Separation Process and Apparatus for Light Noble Gas

ABSTRACT

Process and apparatus for producing helium, neon, or argon product gas using an adsorption separation unit having minimal dead end volumes. A second separation unit receives a stream enriched in helium, neon, or argon, and a stream is recycled from the second separation unit back to the adsorption separation unit in a controlled manner to maintain the concentration of the helium, neon, or argon in the feed to the separation unit within a targeted range.

BACKGROUND

The present disclosure relates to the recovery of a light noble gas from a gas mixture containing the light noble gas and at least one other component. The light noble gas may be helium, neon, or argon.

A variety of processes and techniques have been developed to separate and recover light noble gases from multicomponent gas streams. Such processes include stand-alone membrane separation units, stand-alone cryogenic units, and combinations of membrane separation units, cryogenic units, and pressure swing adsorption (PSA) units. As used herein, the term “pressure swing adsorption” includes “vacuum swing adsorption” and “vacuum pressure swing adsorption.”

Disclosures related to such processes and/or techniques include WO2016/096104; DE102007022963; and U.S. Pat. Nos. 3,250,080; 3,324,626; 4,077,779; 4,690,695; 4,701,187; 4,717,407; 4,783,203; 5,542,966; 8,152,898; 8,268,047; and US 2017/0312682.

It is desirable in the industry to recover light noble gases from various feed streams that contain the desired light noble gas.

For example, it is desirable to recover helium from a feed stream (e.g. natural gas) having a low helium concentration, e.g. from 0.1 mole % to 4 mole % or from 0.1 mole % to 2 mole % helium, or from 0.1 mole % to 1 mole % helium. Other example feed streams include nitrogen rejection unit (NRU) vent streams, CO₂ liquefaction vent streams, recycle streams in manufacturing processes, recovery streams in airship filling processes, reboiler non-condensable vents in air separation units, high pressure gaseous nitrogen (HPGAN) from air separation units, reflux to low pressure columns in air separation units, or liquefied nitrogen storage tank vents.

It is desirable in the industry to recover light noble gases from a feed streams where the concentration of the light noble gas varies over time.

It is also desirable in the industry to produce a product gas containing a light noble gas within target concentration specifications for feed streams where the concentration of the light noble gas varies.

BRIEF SUMMARY

The present invention relates to a process and apparatus for separating a light noble gas from a feed gas stream comprising the light noble gas and at least one other component.

There are several aspects of the invention as outlined below. In the following, the reference numbers and expressions set in parentheses are referring to an example embodiment explained further below with reference to the figures. The reference numbers and expressions are, however, only illustrative and do not limit the aspect to any specific component or feature of the example embodiment. Components and features of any embodiment may be combined with one or more components or features from one or more other embodiments, and all such combinations are considered to be within the scope of the present invention. The aspects can be formulated as claims in which the reference numbers and expressions set in parentheses are omitted or replaced by others as appropriate.

Aspect 1. An apparatus for producing a light noble gas product from a feed gas (11) comprising a light noble gas and at least one other gaseous component, the light noble gas selected from the group consisting of helium, neon, and argon, the apparatus comprising:

-   -   an adsorption separation unit (10), wherein the adsorption         separation unit (10) comprises         -   a plurality of vessels (100 a, 100 b, 100 c, 100 d, 100 e)             each containing a bed of adsorbent;         -   a feed gas header (200) in selective fluid communication             with each of the plurality of vessels (100 a, 100 b, 100 c,             100 d, 100 e);         -   a product gas header (210) in selective fluid communication             with each of the plurality of vessels (100 a, 100 b, 100 c,             100 d, 100 e);         -   a tail gas header (220) in selective fluid communication             with each of the plurality of vessels (100 a, 100 b, 100 c,             100 d, 100 e);         -   process gas transfer lines operatively connecting the             plurality of vessels (100 a, 100 b, 100 c, 100 d, 100 e) to             the feed gas header (200), the product gas header (210), and             the tail gas header (220);         -   each vessel (100) of the plurality of vessels (100 a, 100 b,             100 c, 100 d, 100 e) having process gas transfer lines             associated therewith (101, 102, 103, 104, 105, 106, 107,             108);     -   a plurality of valves in the process gas transfer lines         including a plurality of valves adjacent and associated (110,         111, 112, 113, 114, 115) with each respective vessel (100);     -   wherein the adsorption separation unit (10) has a central         volume, V_(c), of process gas transfer lines (101, 102, 103,         104, 105, 106, 107, 108) associated with each of the respective         vessels (100);     -   wherein the central volume for each respective vessel is the sum         of         -   (i) the volume contained in the process gas transfer lines             associated with the respective vessel connecting the             respective vessel to each valve adjacent (110, 111, 112,             113, 114, 115) the respective vessel (100),         -   (ii) all dead-end volumes (109), if any, connected at a             junction to the respective vessel (100), and         -   (iii) all dead-end volumes, if any, connected at a junction             to any of the process gas transfer lines associated with the             respective vessel (100) that connect the respective vessel             (100) to any valve adjacent (110, 111, 112, 113, 114, 115)             the respective vessel (100);     -   wherein the central volume for each respective vessel includes a         secondary volume, V₂, where the secondary volume is the sum of         -   (i) the volume of all dead-end volumes (109), if any,             connected to the respective vessel (100);         -   (ii) the volume of all dead-end volumes, if any, connected             at a junction to any of the process gas transfer lines             associated with the respective vessel (100) that connect the             respective vessel (100) to any valve adjacent (110, 111,             112, 113, 114, 115) the respective vessel (100), and         -   (iii) the volume of any process gas transfer lines (108), if             any, having a first end terminating in a valve adjacent             (115) the respective vessel (100) that is configured to             permit transfer of process gas to the tail gas header (220)             when open and having a second end terminating at a junction             to any other of the associated process gas transfer lines             (102) that connect the respective vessel (100) to any other             valve adjacent (110) the respective vessel (100); and     -   wherein the secondary volume V₂ is less than 5%, or less than         3%, or less than 1% of the central volume, V_(c), for each         vessel (100).

Aspect 2. The apparatus according to aspect 1 further comprising:

-   -   a second separation unit (20), the second separation unit (20)         having an inlet, a first outlet, and a second outlet, the inlet         in fluid communication with the product gas header (210) of the         adsorption separation unit (10);     -   a gas mixer (60) having a first inlet for receiving a stream of         the feed gas (11), a second inlet in fluid communication with a         source of a second gas (17) having a higher light noble gas         concentration than the feed gas (11), wherein the feed gas         header (200) of the adsorption separation unit (10) is in         downstream fluid communication with the outlet of the gas mixer         (60);     -   a sensor (50) in at least one of (i) a process gas transfer line         (11) supplying the first inlet of the gas mixer (60), (ii) a         process gas transfer line (12) connecting the outlet of the gas         mixer (60) to the feed gas header (200) of the adsorption         separation unit (10), and (iii) the feed gas header (200); and     -   a controller (80) in signal communication with the sensor (50),         the controller (80) operable to control the flow rate of light         noble gas from the source of the second gas (17) to the second         inlet of the gas mixer (60) responsive to signals from the         sensor (50).

Aspect 3. The apparatus according to aspect 2 wherein the second separation unit (20) is an adsorption-type separation unit, a membrane-type separation unit, or a distillation-type separation unit.

Aspect 4. The apparatus according to aspect 2 or aspect 3 wherein the source of the second gas (17) comprises the first outlet of the second separation unit (20).

Aspect 5. The apparatus according to aspect 4 further comprising

-   -   a flow regulator (27) operatively disposed between the second         inlet of the gas mixer (60) and the first outlet of the second         separation unit (20) and in signal communication with the         controller (80);     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the flow         regulator (27) operatively disposed between the second inlet of         the gas mixture (60) and the first outlet of the second         separation unit (20).

Aspect 6. The apparatus according to any one of aspects 2 to 5 wherein the source of the second gas (17) comprises the second outlet of the second separation unit (20).

Aspect 7. The apparatus according to aspect 6 further comprising

-   -   a flow regulator (29) operatively disposed between the second         inlet of the gas mixer (60) and the second outlet of the second         separation unit (20) and in signal communication with the         controller (80);     -   wherein the controller (80) is operable to control the flow rate         of the light noble gas from the source of the second gas (17) to         the second inlet of the gas mixer (60) by adjusting the flow         regulator (29) operatively disposed between the second inlet of         the gas mixer (60) and the second outlet of the second         separation unit (20).

Aspect 8. The apparatus according to any one of aspects 2 to 7

-   -   wherein the source of the second gas (17) comprises a process         gas transfer line (36) which operatively connects the product         gas header (210) to the inlet to the second separation unit         (20).

Aspect 9. The apparatus according to aspect 8 further comprising

-   -   a flow regulator (33) operatively disposed between the second         inlet of the gas mixer (60) and the process gas transfer line         (36) which operatively connects the product gas header (210) of         the adsorption separation unit (10) to the inlet of the second         separation unit (20) and in signal communication with the         controller (80);     -   wherein the controller (80) is operable to control the flow rate         of the light noble gas from the source of the second gas (17) to         the second inlet of the gas mixer (60) by adjusting the flow         regulator (33) operatively disposed between the second inlet of         the gas mixer (60) and the process gas transfer line which         operatively connects the product gas header (210) of the         adsorption separation unit (10) to the inlet of the second         separation unit (20).

Aspect 10. The apparatus according to any one of aspects 2 to 9

-   -   wherein the gas mixer (60) has a third inlet in fluid         communication with the second outlet of the second separation         unit (20).

Aspect 11. The apparatus according to aspect 10 further comprising

-   -   a flow regulator (31) operatively disposed between the third         inlet of the gas mixer (60) and the second outlet of the second         separation unit (20) and in signal communication with the         controller (80);     -   wherein the controller (80) is operable to adjust the flow         regulator (31) operatively disposed between the third inlet of         the gas mixer (60) and the second outlet of the second         separation unit (20) responsive to signals from the sensor (50).

Aspect 12. The apparatus according to any one of aspects 2 to 9

-   -   wherein the gas mixer (60) has a third inlet in fluid         communication with a process gas transfer line (36) which         operatively connects the product gas header (210) of the         adsorption separation unit (10) to the inlet to the second         separation unit (20).

Aspect 13. The apparatus according to aspect 12 further comprising

-   -   a flow regulator (37) operatively disposed between the third         inlet of the gas mixer (60) and the process gas transfer line         (36) which operatively connects the product gas header (210) of         the adsorption separation unit (10) to the inlet to the second         separation unit (20) and in signal communication with the         controller (80);     -   wherein the controller (80) is operable to adjust the flow         regulator (37) operatively disposed between the third inlet of         the gas mixer (60) and the process gas transfer line which         operatively connects the product gas header (210) of the         adsorption separation unit (10) to the inlet to the second         separation unit (20) responsive to signals from the sensor (50).

Aspect 14. The apparatus according to any one of aspects 2 to 13 wherein the second separation unit (20) is a membrane-type separation unit,

-   -   wherein the source of the second gas (17) comprises the first         outlet of the second separation unit (20);     -   wherein the second separation unit (20) comprises one or more         adjustable orifices (26) in signal communication with the         controller (80), the one or more adjustable orifices (26)         operative to control a pressure in the second separation unit         (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the one or more         adjustable orifices (26).

Aspect 15. The apparatus according to any one of aspects 2 to 14 wherein the second separation unit (20) is a membrane-type separation unit,

-   -   wherein the source of the second gas (17) comprises the first         outlet of the second separation unit (20);     -   wherein the membrane-type separation unit comprises a plurality         of membrane modules and one or more control valves that control         the fraction of membrane modules on-stream, the one or more         control valves in signal communication with the controller (80);     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the fraction of         membrane modules on-stream.

Aspect 16. The apparatus according to any one of aspects 2 to 15 wherein the second separation unit (20) is a membrane-type separation unit, wherein the source of the second gas (17) comprises the first outlet of the second separation unit (20), the apparatus further comprising

-   -   a heat exchanger (40) operative to control a temperature in the         second separation unit, the heat exchanger in signal         communication with the controller (80);     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the heat duty of         the heat exchanger (40).

Aspect 17. The apparatus according to any one of aspects 2 to 13 wherein the second separation unit (20) is an adsorption-type separation unit,

-   -   wherein the adsorption-type separation unit comprises a         plurality of vessels each containing a bed of adsorbent, and one         or more control valves that control the fraction of the         plurality of vessels on-stream, the one or more control valves         in signal communication with the controller (80);     -   wherein the source of the second gas comprises the first outlet         of the second separation unit;     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the fraction of         the plurality of vessels on-stream.

Aspect 18. The apparatus according to any one of aspects 2 to 13 or aspect 17 wherein the second separation unit (20) is an adsorption-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit;     -   wherein the second separation unit (20) comprises a feed gas         header,     -   wherein the second separation unit (20) comprises one or more         adjustable orifices (32) operative to control a pressure in the         feed gas header of the second separation unit (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the one or more         adjustable orifices (32) operative to control the pressure in         the feed gas header of the second separation unit (20).

Aspect 19. The apparatus according to any one of aspects 2 to 13 or 17 to 18 wherein the second separation unit (20) is an adsorption-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit;     -   wherein the second separation unit (20) comprises a tail gas         header,     -   wherein the second separation unit (20) comprises one or more         adjustable orifices (27) operative to control a pressure in the         tail gas header of the second separation unit (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the one or more         adjustable orifices (27) operative to control the pressure in         the tail gas header of the second separation unit (20).

Aspect 20. The apparatus according to any one of aspects 2 to 13 or 17 to 18 wherein the second separation unit (20) is an adsorption-type separation unit,

-   -   wherein the source of the second gas comprises the second outlet         of the second separation unit;     -   wherein the second separation unit (20) comprises a product gas         header,     -   wherein the second separation unit (20) comprises one or more         adjustable orifices (26) operative to control a pressure in the         product gas header of the second separation unit (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the one or more         adjustable orifices (26) operative to control the pressure in         the product gas header of the second separation unit (20).

Aspect 21. The apparatus according to any one of aspects 2 to 13 wherein the second separation unit (20) is a distillation-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit (20);     -   wherein the second separation unit comprises one or more         adjustable orifices (26, 27, 32) in signal communication with         the controller (80), the one or more adjustable orifices (26,         27, 32) operative to control a pressure in the second separation         unit (20);     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the one or more         adjustable orifices (26, 27, 32) operative to control the         pressure in the second separation unit (20).

Aspect 22. The apparatus according to any one of aspects 2 to 13 or 21 wherein the second separation unit (20) is a distillation-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit (20);     -   the apparatus further comprising a heat exchanger (40) operative         to control a temperature in the second separation unit, the heat         exchanger in signal communication with the controller (80);     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the heat duty of         the heat exchanger (40).

Aspect 23. The apparatus according to any one of aspects 2 to 13 or 21 to 22 wherein the second separation unit (20) is a distillation-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit (20);     -   wherein the second separation unit (20) comprises one or more         orifices operative to control a reflux ratio in the second         separation unit (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the reflux ratio         in the second separation unit (20).

Aspect 24. The apparatus according to any one of aspects 2 to 13 or 21 to 23 wherein the second separation unit (20) is a distillation-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit (20);     -   wherein the second separation unit (20) comprises one or more         orifices operative to control a distillate to feed ratio in the         second separation unit (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the distillate         to feed ratio in the second separation unit (20).

Aspect 25. The apparatus according to any one of aspects 2 to 13 or 21 to 24 wherein the second separation unit (20) is a distillation-type separation unit,

-   -   wherein the source of the second gas comprises the first outlet         of the second separation unit (20);     -   wherein the second separation unit (20) comprises one or more         orifices operative to control a product to feed ratio in the         second separation unit (20); and     -   wherein the controller (80) is operable to control the flow rate         of light noble gas from the source of the second gas (17) to the         second inlet of the gas mixer (60) by adjusting the distillate         to feed ratio in the second separation unit (20).

Aspect 26. A process for separating a feed gas stream (11) comprising a light noble gas and at least one other gaseous component into a light noble gas-rich stream (25) and a light noble gas-lean stream (14), the light noble gas selected from the group consisting of helium, neon, and argon, the process comprising:

-   -   combining the feed gas stream (11) with a second gas stream (17)         to form a combined gas stream (12), the second gas stream (17)         having higher light noble gas content than the feed gas stream         (11), the second gas stream (17) having a flow rate that is         regulated;     -   separating a first separation unit feed gas stream (15) in an         adsorption separation unit (10) to produce a light noble         gas-enriched stream (13) and the light noble gas-lean stream         (14), wherein the first separation unit feed gas stream (15)         comprises at least a portion of the combined gas stream (12);         and     -   separating a second separation unit feed gas stream (21) in a         second separation unit (20) to produce the light noble gas-rich         stream (25) and a light noble gas-depleted stream (23), wherein         said second separation unit feed gas stream (21) comprises at         least a portion of the light noble gas-enriched stream (13) from         the adsorption separation unit (10);     -   wherein the flow rate of the light noble gas in the second gas         stream (17) is controlled responsive to a measure of the light         noble gas content in at least one of the feed gas stream (11),         the combined gas stream (12), or the first separation unit feed         gas stream (15).

Aspect 27. The process according to aspect 26 wherein the adsorption separation unit (10) comprises:

-   -   a plurality of vessels (100 a, 100 b, 100 c, 100 d, 100 e) each         containing a bed of adsorbent;     -   a feed gas header (200) in selective fluid communication with         each of the plurality of vessels (100 a, 100 b, 100 c, 100 d,         100 e);     -   a product gas header (210) in selective fluid communication with         each of the plurality of vessels (100 a, 100 b, 100 c, 100 d,         100 e);     -   a tail gas header (220) in selective fluid communication with         each of the plurality of vessels (100 a, 100 b, 100 c, 100 d,         100 e);     -   process gas transfer lines operatively connecting the plurality         of vessels (100 a, 100 b, 100 c, 100 d, 100 e) to the feed gas         header (200), the product gas header (210), and the tail gas         header (220);     -   each vessel (100) of the plurality of vessels (100 a, 100 b, 100         c, 100 d, 100 e) having process gas transfer lines associated         therewith (101, 102, 103, 104, 105, 106, 107, 108);     -   a plurality of valves in the process gas transfer lines         including a plurality of valves adjacent and associated (110,         111, 112, 113, 114, 115) with each respective vessel (100);     -   wherein the adsorption separation unit (10) has a central         volume, V_(c), of process gas transfer lines (101, 102, 103,         104, 105, 106, 107, 108) associated with each of the respective         vessels (100),     -   wherein the central volume for each respective vessel is the sum         of         -   (i) the volume contained in the process gas transfer lines             associated with the respective vessel connecting the             respective vessel to each valve adjacent (110, 111, 112,             113, 114, 115) the respective vessel (100),         -   (ii) all dead-end volumes (109), if any, connected at a             junction to the respective vessel (100), and         -   (iii) all dead-end volumes, if any, connected at a junction             to any of the process gas transfer lines associated with the             respective vessel (100) that connect the respective vessel             (100) to any valve adjacent (110, 111, 112, 113, 114, 115)             the respective vessel (100);     -   wherein the central volume for each respective vessel includes a         secondary volume, V₂, where the secondary volume is the sum of         -   (i) the volume of all dead-end volumes (109), if any,             connected to the respective vessel (100);         -   (ii) the volume of all dead-end volumes, if any, connected             at a junction to any of the process gas transfer lines             associated with the respective vessel (100) that connect the             respective vessel (100) to any valve adjacent (110, 111,             112, 113, 114, 115) the respective vessel (100), and         -   (iii) the volume of any process gas transfer lines (108), if             any, having a first end terminating in a valve adjacent             (115) the respective vessel (100) that is configured to             permit transfer of process gas to the tail gas header (220)             when open and having a second end terminating at a junction             to any other of the associated process gas transfer lines             (102) that connect the respective vessel (100) to any other             valve adjacent (110) the respective vessel (100); and     -   wherein the secondary volume, V₂, is less than 5% or less than         3% or less than 1% of the central volume, V_(c), for each vessel         (100).

Aspect 28. The process according to aspect 26 or aspect 27 where the feed gas stream (11) has a total gas molar flow rate, F₁, with a molar flow rate of light noble gas, F_(1, Noble), and the second gas stream (17) has a total gas molar flow rate, F₂, with a molar flow rate of light noble gas, F_(2, Noble), and wherein

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}} \geq 1.$

Aspect 29. The process according to any one of aspects 26 to 28 wherein the second separation unit (20) is an adsorption-type separation unit, a membrane-type separation unit, or a distillation-type separation unit.

Aspect 30. The process according to any one of aspects 26 to 29

-   -   wherein the flow rate of light noble gas in the second gas         stream (17) is increased if the light noble gas content is less         than a desired lower limit; and/or     -   wherein the flow rate of light noble gas in the second gas         stream (17) is decreased if the light noble gas content is         greater than a desired upper limit.

Aspect 31. The process according to any one of aspects 26 to 30 wherein the second gas stream (17) comprises the light noble gas-depleted stream (23), and wherein the flow rate of light noble gas in the second stream (17) is increased or decreased by controlling operating conditions of the second separation unit (20) in response to the light noble gas content.

Aspect 32. The process according to aspect 31 wherein the second separation unit (20) is a membrane-type separation unit and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   decreasing the pressure difference between the second separation         unit feed gas stream (21) and the light noble gas-rich stream         (25) to increase the flow rate of light noble gas in the light         noble gas-depleted stream (23); and/or     -   increasing the pressure difference between the second separation         unit feed gas stream (21) and the light noble gas-rich stream         (25) to decrease the flow rate of light noble gas in the light         noble gas-depleted stream (23).

Aspect 33. The process according to aspect 31 or aspect 32 wherein the second separation unit (20) is a membrane-type separation unit comprising a plurality of membrane modules, and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   decreasing the number of membrane modules on-stream to increase         the flow rate of light noble gas in the light noble gas-depleted         stream (23); and/or     -   increasing the number of membrane modules on-stream to decrease         the flow rate of light noble gas in the light noble gas-depleted         stream (23).

Aspect 34. The process according to any one of aspects 31 to 33 wherein the second separation unit (20) is a membrane-type separation unit, and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   increasing the temperature of the second separation unit feed         gas stream (21) to decrease the flow rate of light noble gas in         the light noble gas-depleted stream (23); and/or     -   decreasing the temperature of the second separation unit feed         gas stream (21) to increase the flow rate of light noble gas in         the light noble gas-depleted stream (23).

Aspect 35. The process according to aspect 31 wherein the second separation unit (20) is an adsorption-type separation unit operating with an adsorption cycle having a cycle time, and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   increasing the cycle time of the second separation unit (20) to         decrease the flow rate of light noble gas in the light noble         gas-depleted stream (23); and/or     -   decreasing the cycle time of the second separation unit (20) to         increase the flow rate of light noble gas in the light noble         gas-depleted stream (23).

Aspect 36. The process according to aspect 31 or 35 wherein the second separation unit (20) is an adsorption-type separation unit having a feed gas header and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   increasing the pressure of the second separation unit feed gas         stream (21) in the feed gas header of the second separation unit         (20) to decrease the flow rate of the light noble gas in the         light noble gas-depleted stream (23); and/or     -   decreasing the pressure of the second separation unit feed gas         stream (21) in the feed gas header of the second separation unit         (20) to increase the flow rate of the light noble gas in the         light noble gas-depleted stream (23).

Aspect 37. The process according to any one of aspects 31, 35, or 36 wherein the second separation unit (20) is an adsorption-type separation unit having a tail gas header and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   increasing the pressure of the light noble gas-depleted stream         (23) in the tail gas header of the second separation unit (20)         to increase the flow rate of the light noble gas in the light         noble gas-depleted stream (23); and/or     -   decreasing the pressure of the light noble gas-depleted stream         (23) in the tail gas header of the second separation unit (20)         to decrease the flow rate of the light noble gas in the light         noble gas-depleted stream (23).

Aspect 38. The process according to any one of aspects 31, or 35 to 37 wherein the second separation unit (20) is an adsorption-type separation unit operating with an adsorption cycle comprising a blowdown step having a target pressure for the end of the blowdown step, where a blowdown gas stream is formed during the blowdown step and wherein controlling operating conditions of the second separation unit (20) comprises

-   -   increasing the target pressure for the end of the blowdown step         to increase the flow rate of the light noble gas in the light         noble gas-depleted stream (23); and/or     -   decreasing the target pressure for the end of the blowdown step         to decrease the flow rate of the light noble gas in the light         noble gas-depleted stream (23).

Aspect 39. The process according to any one of aspects 31, or 35 to 38 wherein the second separation unit (20) is an adsorption-type separation unit comprising a plurality of adsorption beds and operating with a plurality of adsorption cycles each comprising a feed step, wherein controlling the operating conditions of the second separation unit (20) comprises:

-   -   changing to an adsorption cycle having fewer adsorption beds         simultaneously on the feed step to increase the flow rate of         light noble gas in the light noble gas-depleted stream (23);         and/or     -   changing to an adsorption cycle having a greater number of         adsorption beds simultaneously on the feed step to increase the         flow rate of light noble gas in the light noble gas-depleted         stream (23).

Aspect 40. The process according to any one of aspects 31, or 35 to 39 wherein the second separation unit (20) is an adsorption-type separation unit comprising a plurality of adsorption beds and operating with a plurality of adsorption cycles, some comprising a pressure equalization step, wherein controlling the operating conditions of the second separation unit (20) comprises:

-   -   changing to an adsorption cycle having fewer or no pressure         equalization steps to increase the flow rate of light noble gas         in the light noble gas-depleted stream (23); and/or     -   changing to an adsorption cycle having a greater number of         pressure equalization steps to decrease the flow rate of light         noble gas in the light noble gas-depleted stream (23).

Aspect 41. The process according to aspect 31 wherein the second separation unit (20) is a distillation-type separation unit having an operating pressure wherein controlling the operating conditions of the second separation unit (20) comprises:

-   -   decreasing the operating pressure of the second separation unit         (20) to increase the flow rate of light noble gas in the light         noble gas-depleted stream (23); and/or     -   increasing the operating pressure of the second separation unit         (20) to decrease the flow rate of light noble gas in the light         noble gas-depleted stream (23).

Aspect 42. The process according to aspect 31 or aspect 41 wherein the second separation unit (20) is a distillation-type separation unit operating with a reflux ratio wherein controlling the operating conditions of the second separation unit (20) comprises:

-   -   increasing the reflux ratio of the second separation unit (20)         to increase the flow rate of light noble gas in the light noble         gas-depleted stream (23); and/or     -   decreasing the reflux ratio of the second separation unit (20)         to decrease the flow rate of light noble gas in the light noble         gas-depleted stream (23).

Aspect 43. The process according to any one of aspects 31 or 41 to 42 wherein the second separation unit (20) is a distillation-type separation unit having an operating temperature wherein controlling the operating conditions of the second separation unit (20) comprises:

-   -   decreasing the operating temperature of the second separation         unit (20) to increase the flow rate of light noble gas in the         light noble gas-depleted stream (23); and/or     -   increasing the operating temperature of the second separation         unit (20) to decrease the flow rate of light noble gas in the         light noble gas-depleted stream (23).

Aspect 44. The process according to any one of aspects 26 to 43 wherein the second gas stream (17) comprises a portion (28) of the light noble gas-rich stream (25) having a flow rate, and the flow rate of the light noble gas in the second gas steam (17) is increased by increasing the flow rate of the portion (28) of the light noble gas-rich stream (25) and decreased by decreasing the flow rate of the portion (28) of the light noble gas-rich stream (25).

Aspect 45. The process according to any one of aspects 26 to 44 wherein the feed gas stream (11) has a molar concentration of light noble gas ranging from 0.1 mole % to 2.0 mole %, or ranging from 0.1 mole % to 1.0 mole %.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a process flow diagram for a light noble gas recovery process according to the present process and apparatus.

FIG. 2 is a process flow diagram for an adsorption separation unit suitable for the process.

FIG. 3 is a cycle chart for a 5-bed adsorption separation unit suitable for the process.

FIG. 4 is a plot of helium recovery versus % helium in the feed gas.

FIG. 5 is a plot of helium recovery versus helium content in the product stream.

FIG. 6 is a plot of helium content in the product stream versus mole % helium in the feed gas stream.

FIG. 7 shows plots of helium recovery versus % helium in the feed gas stream.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The ensuing detailed description provides preferred exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the ensuing detailed description of the preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments of the invention, it being understood that various changes may be made in the function and arrangement of elements without departing from the scope of the invention as defined by the claims.

The articles “a” or “an” as used herein mean one or more when applied to any feature in embodiments of the present invention described in the specification and claims. The use of “a” and “an” does not limit the meaning to a single feature unless such a limit is specifically stated. The article “the” preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used.

The adjective “any” means one, some, or all, indiscriminately of quantity.

The term “and/or” placed between a first entity and a second entity includes any of the meanings of (1) only the first entity, (2) only the second entity, and (3) the first entity and the second entity. The term “and/or” placed between the last two entities of a list of 3 or more entities means at least one of the entities in the list including any specific combination of entities in this list. For example, “A, B and/or C” has the same meaning as “A and/or B and/or C” and comprises the following combinations of A, B and C: (1) only A, (2) only B, (3) only C, (4) A and B and not C, (5) A and C and not B, (6) B and C and not A, and (7) A and B and C.

The phrase “at least one of” preceding a list of features or entities means one or more of the features or entities in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. For example, “at least one of A, B, or C” (or equivalently “at least one of A, B, and C” or equivalently “at least one of A, B, and/or C”) has the same meaning as “A and/or B and/or C” and comprises the following combinations of A, B and C: (1) only A, (2) only B, (3) only C, (4) A and B and not C, (5) A and C and not B, (6) B and C and not A, and (7) A and B and C.

The term “plurality” means “two or more than two.”

The phrase “at least a portion” means “a portion or all.” The at least a portion of a stream may have the same composition, with the same concentration of each of the species, as the stream from which it is derived. The at least a portion of a stream may have a different concentration of species than that of the stream from which it is derived. The at least a portion of a stream may include only specific species of the stream from which it is derived.

As used herein a “divided portion” of a stream is a portion having the same chemical composition and species concentrations as the stream from which it was taken.

As used herein a “separated portion” of a stream is a portion having a different chemical composition and different species concentrations than the stream from which it was taken. A separated portion may be, for example, a portion formed from separation in a separator.

The term “portion” includes both a “divided portion” and a “separated portion.”

As used herein, “first,” “second,” “third,” etc. are used to distinguish among a plurality of steps and/or features, and is not indicative of the total number, or relative position in time and/or space, unless expressly stated as such.

The terms “depleted” or “lean” mean having a lesser mole % concentration of the indicated component than the original stream from which it was formed. “Depleted” and “lean” do not mean that the stream is completely lacking the indicated component.

The terms “rich” or “enriched” mean having a greater mole % concentration of the indicated component than the original stream from which it was formed.

As used herein, “in fluid communication” or “in fluid flow communication” means operatively connected by one or more conduits, manifolds, valves and the like, for transfer of fluid. A conduit is any pipe, tube, passageway or the like, through which a fluid may be conveyed. An intermediate device, such as a pump, compressor or vessel may be present between a first device in fluid flow communication with a second device unless explicitly stated otherwise.

Downstream and upstream refer to the intended flow direction of the process fluid transferred. If the intended flow direction of the process fluid is from the first device to the second device, the second device is downstream of the first device. In case of a recycle stream, downstream and upstream refer to the first pass of the process fluid.

For the purposes of simplicity and clarity, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.

The present apparatus and process are described with reference to the figures. In this disclosure, a single reference number may be used to identify a process gas stream and the process gas transfer line that carries said process gas stream. Which feature the reference number refers to will be understood depending on the context.

The present apparatus and process are for separating a feed gas 11 containing a light noble gas and at least one other gaseous component into a light noble gas-rich gas 25 and a light noble gas-lean gas 14. The light noble gas may be helium, neon, or argon.

The feed gas 11 may be natural gas. The light noble gas may be helium. The at least one other component may be methane. Another component may be nitrogen. Some natural gas sources are known to comprise methane, nitrogen, and helium.

The feed gas 11 may be a non-condensable vent gas from an air separation unit (ASU). The light noble gas may be neon. The at least one other component may be nitrogen. Another component may be oxygen. Another component may be argon. Air is known to comprise nitrogen, oxygen, argon, and neon.

The feed gas 11 may be natural gas. The light noble gas may be argon. The at least one other component may be methane. Another component may be carbon dioxide. Another component may be nitrogen. Some natural gas sources are known to comprise methane, carbon dioxide, nitrogen, and argon.

The apparatus comprises an adsorption separation unit 10. An adsorption-type separation unit is any separation unit that separates a feed stream into at least two streams using a solid adsorbent, one stream enriched in species that are more adsorbable and another stream enriched in species that are less adsorbable. The adsorption separation unit 10 comprises a plurality of vessels 100 a, 100 b, 100 c, 100 d, 100 e. Each of the plurality of vessels contains a bed of adsorbent suitable for separating the light noble gas from the other components in the feed stream.

Adsorption separation units generally comprise a plurality of adsorption beds containing suitable adsorbent. While FIGS. 1-3 provide an exemplary adsorption unit with five adsorption beds, any suitable number of adsorption beds may be used. In general, the number of adsorption beds used in the adsorption separation unit and process is designed to meet required product purity and light noble gas product recovery.

For a required product purity, the number of beds can be a trade-off between capital and light noble gas recovery. For example, increasing the number of beds allows the adsorption process to utilize a greater number of pressure equalization steps. Pressure equalization steps are light noble gas saving steps. Increasing the number of pressure equalization steps will reduce the pressure at which gas is discharged from the bed to the waste stream, decreasing light noble gas losses. If the pressure equalization steps are conducted through co-current depressurization of the high-pressure bed, the impurity front advances farther when more pressure equalization steps are used. To maintain the desired production, the size of each bed increases in addition to the number of beds.

Alternatively, the number of beds may be increased to lengthen the time available to individual steps that may be limiting the efficiency of the overall process. For example, increasing the number of beds allows the adsorption process to increase the number of beds that will process feed gas or process purge gas. Sending gas to more beds on feed or more beds on purge decreases the velocity of the gas passing over the adsorbent particles, which in turn increases the efficiency of the process step.

Generally, more than one adsorption bed is used so that at least one adsorption bed can be producing product gas while another bed is regenerating. In this way, product gas can be produced on a continuous basis.

FIG. 1 illustrates a 5-bed adsorption separation unit with beds A-E. FIG. 2 illustrates adsorption separation unit 10 with 5 adsorption vessels 100 a, 100 b, 100 c, 100 d, and 100 e. The skilled person can readily select the number of adsorption vessels/beds to use.

The adsorption beds may contain a single adsorbent or multiple adsorbents. In the case of multiple adsorbents, the adsorbents may be interspersed, layered, or a combination thereof.

Suitable adsorbents may be readily selected by those skilled in the art. Suitable adsorbents for separating helium from other gaseous components in natural gas include activated carbon, silica gel, activated alumina, and zeolites such as molecular sieves.

The adsorption separation unit may be operated using any known adsorption cycle suitable for separating a light noble gas from a gas mixture comprising the light noble gas and at least one other gas component. Examples are illustrated in U.S. Pat. No. 4,077,779A and U.S. Pat. No. 774,068B2, which both detail pressure swing adsorption cycles for light gas purification.

The adsorption cycle may be a so-called vacuum pressure swing adsorption (VPSA) cycle.

The adsorption cycle may comprise a production step, a co-current rinse step, a blowdown step, an evacuation step, and a product pressurization step. In the exemplary embodiment shown in FIG. 1, adsorption beds A-E are illustrated with a cycle having a production step (P), a co-current rinse step (R), a blowdown step (BD), an evacuation step (EV), and a product pressurization step (PP). During the adsorption cycle, each of the beds cycle in turn through the cycle steps. The corresponding VPSA cycle table for a 5-bed adsorption separation unit is shown in FIG. 3.

The production step is abbreviated herein as “P”. The production step is also called the feed step and/or adsorption step in the literature.

As shown in FIG. 2, the adsorption separation unit 10 comprises a feed gas header 200. The feed gas header 200 is in selective fluid communication with each of the plurality of vessels 100 a, 100 b, 100 c, 100 d, and 100 e for providing a respective portion of separation unit feed gas stream 12 to each of the plurality of vessels. “Selective” fluid communication means that a valve or equivalent device is used to selectively provide fluid communication between components (i.e. between the feed gas header and each of the plurality of vessels). As shown in FIG. 2, valve 110 a provides selective fluid communication between the feed gas header 200 and adsorption vessel 100 a, valve 110 b provides selective fluid communication between the feed gas header 200 and adsorption vessel 100 b, and so on.

In the embodiment shown in FIGS. 1 and 3, the adsorption vessel feed gas 15 comprises the separation unit feed gas stream 12 and rinse gas effluent 18 from an adsorption vessel undergoing a rinse step. In the embodiment shown in FIG. 2, the feed gas header 200 receives the separation unit feed gas stream 12 and rinse gas effluent 18 from an adsorption vessel undergoing a rinse step via the rinse gas effluent header 250. A rinse gas effluent header 250 may or may not be used depending on the selected adsorption cycle. The separation unit feed gas stream 12 is formed from the feed gas stream 11 and second gas stream 17 (discussed in more detail below).

Adsorption vessel feed gas 15 passes from the feed gas header 200, through a respective open feed gas valve 110 (valve 110 a for vessel 100 a, valve 110 b for vessel 100 b, etc.), and into a respective adsorption vessel 100 for a production step of the adsorption cycle.

In the production step, the adsorption vessel feed gas stream 15 containing the light noble gas (for example helium) is introduced at a feed gas pressure into an adsorption bed undergoing the production step and the secondary gas components (for example CH₄ and N₂) are adsorbed on the adsorbent in the adsorption bed undergoing the production step while a light noble gas-enriched stream 13 is simultaneously withdrawn from the adsorption bed undergoing the production step and passed to a product gas header 210. The product gas header 210 is in selective fluid communication with each of the plurality of vessels 100 a, 100 b, 100 c, 100 d, and 100 e for receiving light noble gas-enriched gas 13 from each of the plurality of vessels when on a production step. The product gas header 210 is in selective fluid communication with each respective vessel 100 by way of a respective product valve 113 (valve 113 a for vessel 100 a, valve 113 b for vessel 100 b, etc.). The light noble gas-enriched gas 13 contains a higher concentration of light noble gas than the adsorption vessel feed gas stream 15 and is depleted of the secondary gas components. The duration of the production step may be any suitable duration, for example from 1 second to 300 seconds, or from 30 seconds to 300 seconds. The skilled person can readily determine a suitable duration for any of the known adsorption cycle steps.

The pressure in the adsorption bed undergoing the production step may range, for example from 0.1 MPa to 3.4 MPa or from 0.3 MPa to 1.2 MPa (absolute pressure).

Each of the adsorption beds has a “feed end” and a “product end,” so termed because of their function during the production step of the adsorption cycle. A feed gas mixture is introduced into the “feed end” of the adsorption bed and a product gas is withdrawn from the “product end” during the production step of the cycle. During other steps of the adsorption cycle, gas may be introduced or withdrawn from “feed end.” Likewise, during other steps of the adsorption cycle, gas may be introduced or withdrawn from the “product end.”

The direction of flow during other steps is typically described with reference to the direction of flow during the production step. Thus, gas flow in the same direction as the gas flow during the production step is “co-current” (sometimes called “concurrent”) and gas flow that is in the opposite direction to the gas flow during the production step is “counter-current.” Co-currently introducing a gas into an adsorption bed means to introduce the gas in the same direction as the feed gas introduced during the production step (i.e. introducing into the feed end). Counter-currently introducing a gas into an adsorption bed means to introduce the gas in a direction opposite to the direction of the feed gas flow during the feed step (i.e. introducing into the product end). Co-currently withdrawing a gas from an adsorption bed means to withdraw the gas in the same direction as the product gas during the production step (i.e. withdrawing from the product end). Counter-currently withdrawing a gas from an adsorption bed means to withdraw the gas in a direction opposite to the direction of the product gas flow during the production step (i.e. withdrawing from the feed end).

The blowdown step, abbreviated “BD”, comprises counter-currently withdrawing a blowdown gas from an adsorption bed undergoing the blowdown step. The blowdown gas has a concentration of the secondary gas components that is higher than the concentration of the secondary gas components in the adsorption vessel feed gas stream 15. The blowdown gas may be withdrawn from the adsorption bed undergoing the counter-current blowdown step until the pressure in the adsorption bed undergoing the counter-current blowdown step reaches a blowdown pressure ranging from 40 kPa to 1000 kPa. The blowdown pressure is the pressure in the adsorption bed at the end of the counter-current blowdown step.

As shown in FIG. 1, the blowdown gas may be passed from the adsorption bed undergoing the blowdown step to a buffer vessel 70 and compressed in compressor 56 to form a rinse gas 19 for the rinse step, “R”. As shown in FIG. 2, blowdown gas is passed to blowdown gas header 230, to buffer vessel 70, to compressor 56, and passed to rinse gas supply header 240. A rinse gas supply header 240 may or may not be used depending on the selected adsorption cycle.

The rinse step is abbreviated “R”. The rinse step comprises co-currently introducing a rinse gas 19 into an adsorption bed undergoing the rinse step while simultaneously co-currently withdrawing a rinse gas effluent 18 from the adsorption bed undergoing the rinse step. During a rinse step, the more strongly adsorbed components displace the less strongly adsorbed components from the adsorbent and void spaces, providing a means to increase the recovery of the less strongly adsorbed components, i.e. the light noble gas. A rinse gas may be formed from the blowdown gas. A rinse gas may also be formed from the light noble gas-depleted stream, an external source of gas which is absent of light noble gas, or any combination thereof.

As shown in FIG. 1, the rinse gas effluent stream 18 may be introduced along with the adsorption separation unit feed gas stream 12 into the adsorption bed undergoing the production step, “P”, as adsorption vessel feed gas stream 15.

Forming a rinse gas from the blowdown gas, in combination with the rinse step, in combination with introducing the rinse gas effluent into the adsorption bed undergoing the production step has the technical effect of increasing the recovery of light noble gas.

As shown in FIG. 1, the adsorption cycle may also include an evacuation step, “EV”. The evacuation step is similar to the blowdown step, with the addition of using a compressor, vacuum pump, or the like, 57 to draw the pressure down below atmospheric pressure. The gas evacuated from the adsorption bed undergoing the evacuation step is passed to a tail gas header 220, and then to a compressor 57 where it is discharged from the compressor 57 as light noble gas-lean stream 14.

The tail gas header 220 is in selective fluid communication with each of the plurality of vessels for receiving light noble gas-lean gas from each of the plurality of vessels. Selective fluid communication between the tail gas header and each of the respective adsorption vessels 100 is provided via valves 115 and 116 (115 a and 116 a for vessel 100 a, 115 b and 116 b for vessel 100 b, etc.). The tail gas header 220 is in fluid communication with an outlet of the adsorption separation unit 10 for discharging the light noble gas-lean gas from the adsorption separation unit 10. For the case where the feed gas stream 11 is natural gas that contains helium, light noble gas-lean stream 14 is natural gas stripped of helium and can be introduced into a natural gas pipeline for any desired use.

Depending on the adsorption cycle used, the blowdown gas header may also be a tail gas header, for example when the blowdown gas is discharged from the adsorption separation unit 10 as a light noble gas-lean gas.

As shown in FIG. 1, the adsorption cycle may also include a product pressurization step, “PP”. The product pressurization step comprises counter-currently introducing a portion of the product gas 16 into the bed to pressurize the vessel. As shown in FIG. 2, product gas 16 may be introduced into a respective adsorption vessel 100 from product gas header 210 via a respective product gas valve 113. Product gas 16 may be introduced into the adsorption bed undergoing the product pressurization step until the adsorption bed undergoing the product pressurization step is substantially at the feed gas pressure.

If desired, the adsorption cycle may include various other adsorption cycle steps, such as pressure equalization steps. Various adsorption cycle steps are discussed, for example, in U.S. Pat. No. 9,381,460.

Adsorption cycles have a cycle time. The cycle time is a well-understood and conventional term in the art. The adsorption separation unit undergoes a repeated series of cycle steps of a defined adsorption cycle. The cycle time is the time period required to complete one adsorption cycle from start to finish.

The plurality of vessels 100 a, 100 b, 100 c, 100 d, 100 e are operatively connected to the various headers 200, 210, 220, 230, 240, and 250 by respective process gas transfer lines 101, 102, 103, 104, 105, 106, 107, and 108. As used herein, process gas transfer lines are any fluid-tight conveyance means for transferring process gas therein, for example, pipes, tubes, conduits, ducts, hoses, etc.

Each vessel of the plurality of vessels 100 a, 100 b, 100 c, 100 d, 100 e have process gas transfer lines associated therewith (process gas transfer lines 101 a, 102 a, 103 a, 104 a, 105 a, 106 a, 107 a, and 108 a for vessel 100 a; process gas transfer lines 101 b, 102 b, 103 b, 104 b, 105 b, 106 b, 107 b, and 108 b for vessel 100 b; process gas transfer lines 101 c, 102 c, 103 c, 104 c, 105 c, 106 c, 107 c, and 108 c for vessel 100 c; process gas transfer lines 101 d, 102 d, 103 d, 104 d, 105 d, 106 d, 107 d, and 108 d for vessel 100 d; and process gas transfer lines 101 e, 102 e, 103 e, 104 e, 105 e, 106 e, 107 e, and 108 e for vessel 100 e). Process gas transfer lines are “associated” with a specific vessel if they provide fluid communication between the specific vessel and an adjacent header. Process gas transfer lines are associated with a specific vessel if they are operatively disposed between the specific vessel and an adjacent header (and not beyond the adjacent header). Referring to FIG. 2, only the “a” process gas transfer lines are associated with vessel 100 a, only the “b” process gas transfer lines are associated with vessel 100 b, only the “c” process gas transfer lines are associated with vessel 100 c, only the “d” process gas transfer lines are associated with vessel 100 d, only the “e” process gas transfer lines are associated with vessel 100 e.

As shown in FIG. 2, there are a plurality of valves (valves 110 a, 111 a, 112 a, 113 a, 114 a, 115 a, and 116 a for vessel 100 a; valves 110 b, 111 b, 112 b, 113 b, 114 b, 115 b, and 116 b for vessel 100 b; valves 110 c, 111 c, 112 c, 113 c, 114 c, 115 c, and 116 c for vessel 100 c; valves 110 d, 111 d, 112 d, 113 d, 114 d, 115 d, and 116 d for vessel 100 d; valves 110 e, 111 e, 112 e, 113 e, 114 e, 115 e, and 116 e for vessel 100 e) in the process gas transfer lines including a plurality of valves adjacent and associated with each respective vessel 100. The valves control the flow of process gas to and from the adsorption vessels 100 a, 100 b, 100 c, 100 d, and 100 e in order to implement the various cycle steps.

Valves are “associated” with a specific vessel if they are operatively disposed between the specific vessel and an adjacent header (and not beyond the adjacent header). A valve associated with a specific vessel can control flow between the specific vessel and an adjacent header.

A valve is “adjacent” the vessel if no other valve is operatively disposed in the process gas transfer line between said valve and the vessel; there is no valve interposed in the process gas transfer line between an adjacent valve and the respective vessel. A valve in a process gas transfer line operatively disposed between a second valve and the vessel, when closed, would prevent process gas flow to the vessel from the second valve or from the vessel to the second valve.

Referring to FIG. 2, valves 110 a, 111 a, 112 a, 113 a, 114 a, and 115 a are associated and adjacent to vessel 100 a. Valve 116 a is associated with vessel 100 a but not adjacent vessel 100 a because valve 115 a is operatively disposed between vessel 100 a and valve 116 a. Likewise, valves 110 b, 111 b, 112 b, 113 b, 114 b, and 115 b are associated and adjacent to vessel 100 b. Valve 116 b is associated with vessel 100 b but not adjacent vessel 100 b because valve 115 b is operatively disposed between vessel 100 b and valve 116 b.

The present apparatus may be characterized by an adsorption separation unit 10 constructed to keep process gas transfer line volume and dead-end volumes that fill with substantial amounts light noble gas during a pressurizing step and empty through the tail gas header during a depressurizing step below a threshold level. These particular volumes carry a significant amount of light noble gas out of the system in a stream that is not captured in the light noble gas product stream. That is, these volumes reduce the light noble gas recovery efficiency.

This separation unit construction may be defined in terms of a central volume and a secondary volume for each of the vessels 100 a, 100 b, 100 c, 100 d, and 100 e, as detailed below.

The central volume for each vessel 100 is a specified volume of process gas transfer lines associated with each respective vessel 100. The central volume for each respective vessel is the sum of:

-   -   (i) the volume contained in the process gas transfer lines         associated with the respective vessel connecting the respective         vessel to each valve adjacent 110, 111, 112, 113, 114, 115 the         respective vessel 100,     -   (ii) all dead-end volumes 109, if any, connected at a junction         to the respective vessel 100, and     -   (iii) all dead-end volumes (not shown), if any, connected at a         junction to any of the process gas transfer lines associated         with the respective vessel 100 that connect the respective         vessel 100 to any valve adjacent 110, 111, 112, 113, 114, 115         the respective vessel 100.

The central volume for a vessel 100 does not include the volume of the vessel itself.

A detailed description of the process gas transfer lines making up the central volume for vessel 100 a will be provided. The process gas transfer lines making up the central volume for vessels 100 b, 100 c, 100 d, and 100 e are to be understood from this detailed description with the necessary changes having been made with regard to the reference numbers (i.e. “b” substituted for “a” for vessel 100 b, “c” substituted for “a” for vessel 100 c, “d” substituted for “a” for vessel 100 d, and “e” substituted for “a” for vessel 100 e).

The central volume for vessel 100 a includes (i) the volume contained in the process gas transfer lines associated with vessel 100 a connecting vessel 100 a to each valve adjacent vessel 100 a. With reference to FIG. 2, the valves adjacent vessel 100 a include valves 110 a, 111 a, 112 a, 113 a, 114 a, and 115 a. The process gas transfer lines associated with vessel 100 a and that connect vessel 100 a to these valves include process gas transfer lines 102 a, 103 a, 104 a, 105 a, 107 a and 108 a. Process gas transfer line 102 a connects vessel 100 a to adjacent valve 110 a. Process gas transfer line 103 a connects vessel 100 a to adjacent valve 111 a. Process gas transfer line 104 a connects vessel 100 a to adjacent valve 112 a. Process gas transfer line 105 a connects vessel 100 a to adjacent valve 113 a. Process gas transfer line 107 a connects vessel 100 a to adjacent valve 114 a. Process gas transfer line 108 a connects vessel 100 a to adjacent valve 115 a.

The central volume for vessel 100 a includes (ii) all dead-end volumes, if any, connected at a junction to the respective vessel 100.

A “dead-end volume” is defined as a volume in continuous open fluid communication with the respective vessel that permits ingress and egress of process gas only at the junction of the dead-end volume. “Continuous open fluid communication” means that the dead-end volume is continuously in fluid communication with the respective vessel during the process. No valve or other device cuts off fluid communication of the dead-end volume from the respective vessel.

Referring to FIG. 2, process gas sensor line 109 a is such a dead-end volume.

The adsorption separation unit 10 may be constructed so as to have no dead-end volumes connected at a junction to any of the vessels 100.

The central volume for vessel 100 a includes (iii) all dead-end volumes, if any, connected at a junction to any of the process gas transfer lines associated with vessel 100 a that connects vessel 100 a to any valve adjacent 110 a, 111 a, 112 a, 113 a, 114 a, 115 a vessel 100 a. The process gas transfer lines associated with vessel 100 a that connect vessel 100 a to adjacent valves 110 a, 111 a, 112 a, 113 a, 114 a, 115 a include process gas transfer lines 102 a, 103 a, 104 a, 105 a, 107 a, and 108 a. FIG. 2 shows no such dead-end volumes. However, one such dead-end volume would exist if sensor line 109 a were moved to form a junction with process gas transfer line 105 a instead of the junction with vessel 100 a.

The central volume for each vessel has a respective volume amount, V_(c).

The central volume for each respective vessel includes a secondary volume which is a subset of the central volume. The secondary volume is the undesired volume that reduces the light noble gas recovery efficiency.

The secondary volume for each respective vessel 100 is the sum of:

-   -   (i) the volume of all dead-end volumes, if any, connected to the         respective vessel 100,     -   (ii) the volume of all dead-end volumes, if any, connected at a         junction to any of the process gas transfer lines associated         with the respective vessel 100 that connect the respective         vessel 100 to any valve adjacent 110, 111, 112, 113, 114, 115         the respective vessel 100, and     -   (iii) the volume of any process gas transfer lines, if any,         having a first end terminating in a valve adjacent the         respective vessel 100 that is configured to permit transfer of         process gas to the tail gas header 220 when open and having a         second end terminating at a junction to any other of the         associated process gas transfer lines that connect the         respective vessel 100 to any other valve adjacent 110 the         respective vessel 100.

The secondary volume for a vessel 100 does not include the volume of the vessel itself.

A detailed description of the process gas transfer lines making up the secondary volume for vessel 100 a will be provided. The process gas transfer lines making up the secondary volume for vessels 100 b, 100 c, 100 d, and 100 e are to be understood from this detailed description with the necessary changes having been made with regard to the reference numbers (i.e. “b” substituted for “a” for vessel 100 b, “c” substituted for “a” for vessel 100 c, “d” substituted for “a” for vessel 100 d, and “e” substituted for “a” for vessel 100 e).

The secondary volume for vessel 100 a includes (i) all dead-end volumes, if any, connected at a junction to the respective vessel 100.

Referring to FIG. 2, process gas sensor line 109 a is such a dead-end volume according to criteria (i).

The adsorption separation unit 10 may be constructed so as to have no dead-end volumes connected at a junction to any of the vessels 100.

The secondary volume for vessel 100 a includes (ii) all dead-end volumes, if any, connected at a junction to any of the process gas transfer lines associated with vessel 100 a that connects vessel 100 a to any valve adjacent 110 a, 111 a, 112 a, 113 a, 114 a, 115 a vessel 100 a. The process gas transfer lines associated with vessel 100 a that connect vessel 100 a to adjacent valves 110 a, 111 a, 112 a, 113 a, 114 a, 115 a include process gas transfer lines 102 a, 103 a, 104 a, 105 a, 107 a, and 108 a. FIG. 2 shows no such dead-end volumes. However, one such dead-end volume would exist if sensor line 109 a were moved to form a junction with process gas transfer line 105 a instead of the junction with vessel 100 a.

The secondary volume for vessel 100 a includes (iii) the volume of any process gas transfer lines, if any, having a first end terminating in a valve adjacent the respective vessel 100 a that is configured to permit transfer of process gas to the tail gas header 220 when open and having a second end terminating at a junction to any other of the associated process gas transfer lines that connect the respective vessel 100 a to any other valve adjacent the respective vessel 100 a. Referring to FIG. 2, process gas transfer line 108 a has a first end terminating in valve 115 a which is adjacent vessel 100 a. Valve 115 a is configured to permit transfer of process gas to the tail gas header 220 when open. Process gas transfer line 108 a has a second end terminating at a junction with process gas transfer line 102 a which connects vessel 100 a to valve 110 a which is adjacent vessel 100 a. Process gas transfer line 108 a is therefore such a volume contributing to the secondary volume as per criteria (iii).

Each vessel has a respective secondary volume, V₂.

We have discovered that the secondary volume of an adsorption-type separation unit has an impact on the recovery efficiency of light noble gas where the feed gas composition has a low concentration of the light noble gas.

By providing an adsorption-type separation unit with a secondary volume which is much smaller than the central volume, more of the light noble gas can be fed to a second separation unit to meet the final product purity specifications for the system.

It is desirable, therefore, to construct the adsorption separation unit 10 with a secondary volume that is small relative to the central volume. The secondary volume, V₂, may be less than 5%, or less than 3%, or less than 1% of the central volume, V_(c), for each vessel 100. The secondary volume, V₂, may be 0.

Isolation valves (not shown) may be used to reduce the secondary volume. For example, with reference to vessel 100 a in FIG. 2, an isolation valve (not shown) may be positioned in process gas transfer line 102 a between vessel 100 a and valve 115 a. In this instance, valve 115 a is no longer an adjacent valve. The isolation valve can be operated to prevent process gas transfer line 108 a from filling with product gas having a higher concentration of light noble gas during repressurization. Process gas transfer line 108 a may be instead repressurized in the rinse step with a rinse gas having a lower concentration of light noble gas. However, using isolation valves adds further complexity with regard to the timing of opening and closing the isolation valves during the adsorption cycle.

Also not shown are process gas transfer lines and valves associated with each of the vessels for bypass, vent, startup, shutdown, maintenance and the like, which are well-known and customary for adsorption separation units. These process gas transfer lines may also contribute to the central volume and secondary volume.

The present apparatus may further comprise a second separation unit 20. The second separation unit may be an adsorption-type separation unit, a membrane-type separation unit, or a distillation-type separation unit.

An adsorption-type separation unit is any separation unit that separates a feed stream into at least two streams using adsorption, each stream having a different concentration of species. As used herein, the term “adsorption” includes any separation which separates components by their relative adhesion of species (atoms, ions, or molecules) to an adsorbent surface.

A membrane-type separation unit is any separation unit that separates a feed stream into two streams using a membrane, each stream having a different concentration of species. The membrane can be a semipermeable membrane or a selectively permeable membrane. Membranes separate gas mixtures by allowing certain gas species to pass through the membrane by diffusion, facilitated diffusion, passive transport, and/or active transport.

A distillation-type separation unit is any separation unit that separates a feed stream into two streams using distillation, each stream having a different concentration of species. As used herein, the term “distillation” includes any separation which separates components by their relative volatilities. Other terms used in the industry include fractionation, rectification, and partial condensation.

The second separation unit 20 has an inlet, a first outlet, and a second outlet. The inlet is in fluid communication with the product gas header 210 of the adsorption separation unit 10. The inlet of the second separation unit 20 is operatively disposed to receive at least a portion of the light noble gas-enriched gas 13 from the product gas header 210. A light noble gas-depleted gas 23 is discharged from the first outlet of the second separation unit 20. A light noble gas-rich gas 25 is discharged from the second outlet of the second separation unit 20.

The present apparatus may comprise a gas mixer 60. The gas mixer 60 has a first inlet for receiving a stream of the feed gas 11, a second inlet in fluid communication with a source of a second gas 17, and an outlet. The gas mixer 60 may be a mixing tee, mixing vessel, static mixer, or any other suitable mixing device capable of combining multiple streams to form a blended stream comprising the multiple streams. The second inlet of the gas mixer 60 receives a second gas 17 from a source of the second gas where the second gas has a higher light noble gas content than the feed gas 11. The source of the second gas may be the first outlet of the second separation unit 20. The second gas 17 may comprise the light noble gas-depleted gas 23 from the second separation unit 20. The apparatus may comprise a compressor 45 to compress the light noble gas-depleted gas 23 before the light noble gas-depleted gas 23 is fed to the gas mixer 60. A separation unit feed gas 12 is formed from the feed gas 11 and the light noble gas-depleted gas 23 and is discharged from the outlet of the gas mixer 60 and passed to the feed gas header 200 of the adsorption separation unit 10.

The feed gas header 200 of the adsorption separation unit 10 is in downstream fluid communication with the outlet of the gas mixer 60. The feed gas header 200 of the adsorption separation unit 10 is operatively disposed to receive the separation unit feed gas 12 from the gas mixer 60.

The present apparatus may comprise a sensor 50 operatively disposed to detect a measure of the helium content and transmit signals responsive to the helium content. The sensor 50 may be located in a process gas transfer line 11 supplying the first inlet of the gas mixer 60. At this location, the sensor 50 would be operatively disposed to detect a measure of the light noble gas content in the feed gas 11. As shown in FIG. 1, the sensor may be located in a process gas transfer line 12 connecting the outlet of the gas mixer 60 to the feed gas header 200 of the adsorption separation unit 10. At this location, the sensor 50 is operatively disposed to detect a measure of the light noble gas content in the separation unit feed gas 12. Alternatively, the sensor 50 may be located in the feed gas header 200. In this location, the sensor 50 would be operatively disposed to detect a measure of the light noble gas content in the adsorption vessel feed gas 15.

More than one sensor 50 may be used. In case more than one sensor 50 is used, one or more sensors may be present in the process gas transfer line 11 supplying the first inlet of the gas mixer 60 and/or the process gas transfer line 12 connecting the outlet of the gas mixer 60 to the feed gas header 200 of the adsorption separation unit 10 and/or in the feed gas header 200.

The measure of the light noble gas content may be a light noble gas concentration. The measured light noble gas concentration may be determined by a concentration sensor 50 that detects the light noble gas concentration. The measured light noble gas concentration may be a mole fraction, mass fraction, mole %, mass %, volume %, or any other suitable concentration unit. The light noble gas concentration may be in any light noble gas concentration units.

The present apparatus may comprise a controller 80 in signal communication with the sensor 50. The signal communication may be wireless or hard-wired. The controller is operable to control operating conditions of the second separation unit 20 responsive to signals from the sensor 50. The second separation unit 20 is controlled to regulate the flow rate of the light noble gas in the second gas stream 17 responsive to the measure of the light noble gas content.

The second inlet of the gas mixer 60 may be in fluid communication with the second outlet of the second separation unit 20. The gas mixer 60 may receive a portion 28 of the light noble gas-rich gas 25 from the second separation unit 20.

The second separation unit 20 may comprise a flow regulator 29 operatively disposed between the second inlet of the gas mixer 60 and the second outlet of the second separation unit 20. The controller 80 may be operable to control the second separation unit 20 by adjusting the flow regulator 29. The flow regulator regulates the flow rate of the portion 28 of the light noble gas-rich gas 25 from the second separation unit 20 to the gas mixer 60 to change the content of light noble gas feed to the adsorption separation unit 10. The controller 80 adjusts the flow regulator 29 responsive to measure of the light noble gas content as determined by sensor 50.

The source of the second gas 17 may comprise a process gas transfer line 36 which operatively connects the product gas header 210 to the inlet to the second separation unit 20. The second inlet of the gas mixer 60 may be in fluid communication with the process gas transfer line 36.

The apparatus may comprise a flow regulator 33 operatively disposed between the second inlet of the gas mixer 60 and the process gas transfer line 36. The flow regulator 33 may be in signal communication with the controller 80. The signal communication may be wireless or hard-wired. The controller 80 may be operable to control the flow rate of the light noble gas from the process gas transfer line 36 by adjusting the flow regulator 33 operatively disposed between the second inlet of the gas mixer 60 and the process gas transfer line 36. Flow regulator 33 may regulate the flow rate of a portion of a light noble gas-enriched stream from the adsorption separation unit 10 to the second inlet of the gas mixer 60 to change the content of light noble gas fed to the adsorption separation unit 10. Controller 80 may adjust flow regulator 33 responsive to the measure of the light noble gas content as determined by sensor 50.

In another embodiment, the gas mixer 60 may have a third inlet. The third inlet may be in fluid communication with the second outlet of the second separation unit 20. The third inlet of the gas mixer 60 may receive a portion 28 of the light noble gas-rich gas 25 from the second separation unit 20.

The second separation unit 20 may comprise a flow regulator 31 in signal communication with controller 80 and operatively disposed between the third inlet of the gas mixer 60 and the second outlet of the second separation unit 20. The controller 80 is operable to control the second separation unit 20 by adjusting the flow regulator 31. The flow regulator 31 regulates the flow rate of the portion 28 of the light noble gas-rich gas 25 from the second separation unit 20 to the third inlet of the gas mixer 60 to change the content of light noble gas feed to the adsorption separation unit 10. The controller 80 adjusts the flow regulator 31 responsive to the measure of the light noble gas content as determined by sensor 50.

Alternatively, or in addition, the third inlet of the gas mixer 60 may be in fluid communication with a process gas transfer line 36 which operatively connects the product gas header 210 of the adsorption separation unit 10 to the inlet to the second separation unit 20.

The apparatus may comprise a flow regulator 37 operatively disposed between the third inlet of the gas mixer 60 and the process gas transfer line 36. The flow regulator 37 may be in signal communication with the controller 80. The signal communication may be wireless or hard-wired. The controller 80 may be operable to control the flow rate of the light noble gas from the process gas transfer line 36 by adjusting the flow regulator 37 operatively disposed between the third inlet of the gas mixer 60 and the process gas transfer line 36. Flow regulator 37 may regulate the flow rate of a portion of a light noble gas-enriched stream from the adsorption separation unit 10 to the third inlet of the gas mixer 60 to change the content of light noble gas fed to the adsorption separation unit 10. Controller 80 may adjust flow regulator 37 responsive to the measure of the light noble gas content as determined by sensor 50.

The second separation unit 20 may be a membrane-type separation unit. The membrane separation unit can be any membrane device with some selectivity for separating the light noble gas from the other components in the feed when a pressure differential is maintained across the membrane. When the light noble gas is helium, the helium permeability through the membrane is typically greater than that of the other components present in the feed to the membrane. Consequently, the concentration of helium in the non-permeate stream from the membrane separation unit is less than its concentration in the feed stream entering the membrane separation unit. Generally, the pressure of the helium-depleted non-permeate stream is 10-200 kPa absolute lower than the feed stream to the membrane separation unit. The light noble gas-rich permeate stream may have a pressure that is 100 kPa to 500 kPa or 100 kPa to 350 kPa lower than the feed stream to the membrane separation unit. A higher permeability of helium and/or its selectivity through the membrane is desirable and results in a beneficial effect on the performance of the overall system.

When the second separation unit 20 is a membrane-type separation unit, the membrane unit may consist of a single membrane device or, alternatively, several membrane devices configured and operated so as to achieve the separation in the most efficient manner, e.g., a cascade of membranes with internal recycle streams between various stages of the membrane unit. Typically, the membrane devices are manufactured in modules, each having certain semi-permeable membrane areas for permeation.

Membrane separation units with some selectivity for separating light noble gases such as helium and neon are available commercially, for example, from Air Products, L′Air Liquide, Ube, Cameron, and UOP.

As shown in FIG. 1, the apparatus may comprise a buffer tank 30 and the light noble gas-enriched stream 13 may be passed from the adsorption separation unit 10 to buffer tank 30 before being passed to the second membrane separation unit 20. The buffer tank buffers the fluctuation in pressure and light noble gas concentration of the light noble gas-enriched stream 13 from the adsorption separation unit 10. Uniform light noble gas concentration and pressure improve controllability of the second separation unit 20, particularly when the second separation unit is a membrane-type unit.

The membrane-type separation unit may comprise one or more adjustable orifices 26 operative to control a pressure in the membrane-type separation unit. The one or more adjustable orifices are operative to control the pressure difference between the second (membrane) separation unit feed gas stream 21 and the light noble gas-rich (permeate) stream 25.

The one or more adjustable orifices may be valves or functionally equivalent means for controlling flow and/or pressure. FIG. 1 shows a valve 26 in fluid communication with the second outlet of the second (membrane) separation unit 20 and a valve 27 in fluid communication with the first outlet of the second (membrane) separation unit 20. The valves 26 and 27 can be adjusted to control the pressure difference between the second separation unit feed gas stream 21 and the light noble gas-rich (permeate) stream 25.

The pressure difference between the second (membrane) separation unit feed gas stream 21 and the light noble gas-rich (permeate) stream 25 may be increased or decreased by changing the percent open of the adjustable orifice (i.e. valve 27) in fluid communication with the first outlet for discharging the light noble gas-depleted (non-permeate) stream 23, and the percent open of the adjustable orifice (i.e. valve 26) in fluid communication with the second outlet for discharging the light noble gas-rich (permeate) stream 25.

The one or more adjustable orifices may be a valve or similar device capable of controlling pressure in the membrane-type separation unit. The one or more adjustable orifices may be in signal communication with the controller 80. The controller may be operable to control the second separation unit 20 by adjusting the one or more adjustable orifices 26. Increasing the back-pressure on the permeate side of the membrane-type separation unit increases the flow rate of light noble gas in the light noble gas-depleted (non-permeate) stream. Decreasing the back-pressure on the permeate side of the membrane-type separation unit decreases the flow rate of light noble gas in the light noble gas-depleted (non-permeate) stream.

The membrane-type separation unit may comprise a plurality of membrane modules and one or more control valves that control the fraction of membrane modules on-stream. The one or more control valves may be in signal communication with the controller 80. The controller may be operable to control the second separation unit 20 by adjusting the fraction of membrane modules on-stream. Increasing the fraction of membrane modules on-stream decreases the flow rate of light noble gas in the light noble gas-depleted (non-permeate) stream. Decreasing the fraction of membrane modules on-stream increases the flow rate of light noble gas in the light noble gas-depleted (non-permeate) stream.

The membrane-type separation unit may comprise a heat exchanger 40. The heat exchanger 40 may be operative to control a temperature in the second separation unit 20. The heat exchanger is operatively disposed to selectively heat or cool at least a portion of the second separation unit feed gas stream 21 by indirect heat transfer with a heat transfer medium. The heat transfer medium may be a heat transfer fluid.

The heat exchanger 40 may be in signal communication with the controller 80. The signal communication may be wireless or hard-wired. The controller 80 may be operable to control the membrane-type separation unit by adjusting the heat duty of the heat exchanger 40. Increasing the temperature of the stream entering the membrane-type separation unit decreases the flow rate of light noble gas in the light noble gas-depleted (non-permeate) stream. Decreasing the temperature of the stream entering the membrane-type separation unit increases the flow rate of light noble gas in the light noble gas-depleted (non-permeate) stream.

As shown in FIG. 1, the second separation unit 20 may comprise a compressor 35 to compress the second separation unit feed gas stream 21.

The second separation unit 20 may be an adsorption-type separation unit.

The adsorption-type separation unit may comprise a plurality of vessels where each vessel contains a bed of adsorbent. The adsorption-type separation unit may comprise one or more control valves that control the fraction of the plurality of vessels that are on-stream. An adsorption bed is “on-stream” if it is undergoing an adsorption cycle to form the light noble gas-depleted stream and the light noble gas-rich stream. An adsorption bed is “off-line” if it is idle while other adsorption beds in the system are undergoing an adsorption cycle. The one or more control valves may be in signal communication with the controller 80. The signal communication may be wireless or hard-wired.

The source of the second gas may be the first outlet of the second separation unit. The controller 80 may be operable to control the flow rate of light noble gas from the first outlet of the second separation unit to the second inlet of the gas mixer 60 by adjusting the fraction of the plurality of vessels on-stream. Increasing the fraction of the plurality of vessels on-stream decreases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the fraction of the plurality of vessels on-stream increases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may be the first outlet of the second separation unit where the second separation unit 20 comprises a feed gas header and one or more adjustable orifices 32 operative to control a pressure in the feed gas header. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the one or more adjustable orifices 32 operative to control the pressure in the feed gas header of the second separation unit 20. The one or more adjustable orifices 32 may be valves. Increasing the pressure in the feed gas header decreases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the pressure in the feed gas header increases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may be the first outlet of the second separation unit where the second separation unit 20 comprises a tail gas header and one or more adjustable orifices 27 operative to control a pressure in the tail gas header. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the one or more adjustable orifices 27 to control the pressure in the tail gas header. The one or more adjustable orifices 27 may be valves. Increasing the pressure in the tail gas header increases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the pressure in the tail gas header decreases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may comprise the second outlet of the second separation unit where the second separation unit 20 comprises a product gas header and one or more adjustable orifices 29 operative to control a pressure in the product gas header. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the one or more adjustable orifices 29 to control the pressure in the product gas header. Increasing the pressure in the product gas header decreases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the pressure in the product gas header increases the flow rate of light noble gas in the light noble gas-depleted stream.

The second separation unit 20 may be a distillation-type separation unit.

The source of the second gas may be the first outlet of the second separation unit 20 where the second separation unit comprises one or more adjustable orifices 26, 27, 32 in signal communication with the controller 80 operative to control a pressure in the second separation unit 20. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the one or more adjustable orifices 26, 27, 32 to control the pressure in the second separation unit 20. Increasing the pressure in the distillation-type separation unit (i.e. a distillation column) increases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the pressure in the distillation-type separation unit (i.e. a distillation column) decreases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may be the first outlet of the second separation unit (20) where the apparatus further comprises a heat exchanger 40 in signal communication with the controller 80. The heat exchanger 40 may be operative to control a temperature in the second separation unit. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer (60) by adjusting the heat duty of the heat exchanger 40. Increasing the heat (temperature) from the heat exchanger increases the temperature in the distillation column which increases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the heat (temperature) from the heat exchanger decreases the temperature in the distillation column which decreases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may be the first outlet of the second separation unit 20 where the second separation unit 20 comprises one or more orifices operative to control a reflux ratio in the second separation unit 20. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the reflux ratio in the second separation unit 20. The “reflux ratio” is defined as the molar flow rate of reflux, which is liquid flow to the top stage of the distillation column, divided by the molar flow rate of the vapor or overhead product (i.e. distillate withdrawn from the second outlet). Increasing the reflux ratio increases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the reflux ratio decreases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may be the first outlet of the second separation unit 20 where the second separation unit 20 comprises one or more orifices operative to control a distillate to feed ratio in the second separation unit 20. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the distillate to feed ratio in the second separation unit 20. The “distillate to feed ratio” is defined as the molar flow rate of vapor or overhead product from the distillation column (i.e. distillate withdrawn from the second outlet), divided by the molar flow rate of feed fed to the distillation column. Increasing the distillate to feed ratio decreases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the distillate to feed ratio increases the flow rate of light noble gas in the light noble gas-depleted stream.

The source of the second gas may be the first outlet of the second separation unit (20) where the second separation unit 20 comprises one or more orifices operative to control a boilup ratio in the second separation unit 20. The controller 80 may be operable to control the flow rate of light noble gas from the source of the second gas 17 to the second inlet of the gas mixer 60 by adjusting the boilup to feed ratio in the second separation unit 20. The “boilup ratio” is defined as the molar flow rate of boilup, which is the vapor flow rate to the bottom stage of the distillation column divided by the molar flow rate of the liquid or bottom product (i.e. bottoms stream withdrawn from the first outlet). Increasing the boilup ratio decreases the flow rate of light noble gas in the light noble gas-depleted stream. Decreasing the boilup ratio increases the flow rate of light noble gas in the light noble gas-depleted stream

The present process comprises combining the feed gas stream 11 with a second gas stream 17 to form a first separation unit feed gas stream 12. The second gas stream 17 has higher light noble gas content than the feed gas stream 11. The feed gas stream 11 may be combined with the second gas stream 17 in gas mixer 60. The second gas stream 17 has a flow rate that is regulated by a regulator, for example, a flow control valve.

The feed gas stream 11 may be characterized by having a low concentration of light noble gas. The feed gas stream may have a molar concentration of light noble gas ranging from 0.1 mole % light noble gas to 2.0 mole % light noble gas, or ranging from 0.1 mole % light noble gas to 1.0 mole % light noble gas.

The present process comprises separating the first separation unit feed gas stream 12 in an adsorption separation unit 10 to produce a light noble gas-enriched stream 13 and the light noble gas-lean stream 14. The adsorption separation unit 10 is an adsorption-type separation unit.

Adsorption cycles have a cycle time. The cycle time is a well-understood and conventional term in the art. The adsorption separation unit undergoes a repeated series of cycle steps of a defined adsorption cycle. The cycle time is the time period required to complete one adsorption cycle from start to finish.

The cycle time of the adsorption cycle may be set to provide the light noble gas-enriched stream 13 having a bulk average (“mixing cup” average) light noble gas concentration ranging from 40 mole % to 90 mole % for the set cycle time. Contrary to conventional operation, the cycle time for the present process is extended to provide lower bulk average light noble gas concentrations for the light noble gas-enriched stream 13 leaving the adsorption separation unit 10. Operating the adsorption separation unit 10 with a longer cycle time increases the recovery of the light noble gas. Due to the low concentrations of light noble gas in the feed gas stream, high recovery is necessary to be commercially viable.

The present process comprises separating a second separation unit feed gas stream 21 in a second separation unit 20 to produce the light noble gas-rich stream 25 and a light noble gas-depleted stream 23. The second separation unit feed gas stream 21 comprises the light noble gas-enriched stream 13 from the adsorption separation unit 10. The second separation unit 20 may be a membrane-type separation unit, an adsorption-type separation unit, or a distillation-type separation unit.

In the present process, the flow rate of the light noble gas in the second gas stream 17 is controlled responsive to a measure of the light noble gas content in at least one of the feed gas stream 11, the first separation unit feed gas stream 12, or an adsorption vessel feed gas stream 15. The adsorption vessel feed gas stream 15 comprises at least a portion of the first separation unit feed gas stream 12.

The light noble gas content may be expressed as a concentration or a relative amount in the stream.

The measure of the light noble gas content may be determined from a measurement of the light noble gas content. The measure of the light noble gas content may be expressed as a volume, molar, or mass concentration of the light noble gas. The measure of the light noble gas content may be expressed as a volume, molar, or mass fraction or percentage of the light noble gas in the mixture.

The measure of light noble gas content in the first separation unit feed gas stream 15 may be the concentration of light noble gas in the feed gas stream 11.

The flow rate of the light noble gas in a stream may be expressed as a volumetric, molar, or mass flow rate.

The feed gas stream 11 may have a total gas molar flow rate, F₁, with an individual gas component molar flow rate of light noble gas, F_(1, Noble). The second gas stream 17 may have a total gas molar flow rate, F₂, with an individual gas component molar flow rate of light noble gas, F_(2, Noble). The process is characterized by recycling a greater molar flow rate of helium to the feed to the adsorption separation unit compared to processes described in the prior art. In the present process

${\frac{F_{2,{Noble}}}{F_{1,{Noble}}} \geq 1},$

where F_(1, Noble) is the molar flow rate of light noble gas in the feed gas stream 11, and F_(2, Noble) is the molar flow rate of light noble gas in the light noble gas-depleted stream 23. Recycling a higher molar flow rate of light noble gas from the second separation unit 20 to the feed to the adsorption separation unit 10 maintains stable feed concentration to the adsorption separation unit 10. This enables the adsorption separation unit 10 to provide constant light noble gas-rich gas to the second separation unit 20, both in flow and concentration, which is necessary for final light noble gas product purity from the second separation unit 20. FIG. 6 shows the effect of changing adsorption feed gas concentration on the adsorption unit product concentration.

For instance, if the feed concentration of helium in stream 11 were to drop from 2.0% to 0.5% over time, which is common in natural gases, the helium product purity of the adsorption unit 10 would decrease from 88% to 67%. This decrease in product purity is caused by the constraint of maintaining the adsorption unit recovery to maximize helium production. However, this decrease in helium product purity may lead to a decrease in the noble gas rich purity from the second separation unit because it may not be possible to operate effectively at the lower second separation unit helium concentration/purity.

In addition, recycling a higher molar flow rate of light noble gas from the second separation unit 20 to the feed of the adsorption-type separation unit 10 increases the recovery of that unit. This effectively increases the overall recovery of the system as the adsorption-type unit 10 is the only significant source of helium losses.

The process may be characterized by

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}} \geq 1.$

The ratio of light noble gas molar flow rates,

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}}$

may be less than or equal to 16. At

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}}$

greater than 16, significant volumes of light noble gas are recycled to the adsorption separation unit 10, and at this point the benefit of recycling light noble gas deteriorates and there is no further practical enhancement of the adsorption-type separation unit 10.

Allie (U.S. Pat. No. 8,268,047) provides an example for helium purification with two VPSA in series with a first outlet stream returned to the first separation unit. From the example the ratio of noble gas (helium) flow from the second separation unit to the first divided by the noble gas flow in the feed

$\left( \frac{F_{2,{Noble}}}{F_{1,{Noble}}} \right)$

is calculated as 0.528. In U.S. Pat. No. 5,080,694 by Knoblauch et al., a similar arrangement to Allie, of unit operations with recycle, is utilized again for helium purification. Per the values in Table 5 from example provided,

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}}$

of Knoblauch is calculated as 0.222. D'Amico et al. (U.S. Pat. No. 5,542,966) again utilizes the same arrangement as Allie and Knoblauch et al. for helium purification. The values provided in the example of D'Amico yield a

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}}$

ratio of 0.408. Finally, Choe et al. (U.S. Pat. No. 4,717,407) employ a process with a cryogenic-type unit as the first separation unit followed by a membrane as the second separation unit, with a first outlet stream returned to the first separation unit. In the second example using values in Table 4 for helium purification,

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}}$

of Choe is calculated as 0.077.

The flow rate of light noble gas in the second gas stream 17 may be increased if the light noble gas content is less than a desired lower limit.

The flow rate of light noble gas in the second gas stream 17 may be decreased if the light noble gas content is greater than a desired upper limit.

The desired lower limit for the light noble gas content of the first separation unit feed gas stream 12 may correspond to a light noble gas mole fraction selected in a range from 0.1 mole % to 0.5 mole %. The desired upper limit for the light noble gas content of the feed gas stream 12 may correspond to a light noble gas mole fraction selected in a range from 1.0 mole % to 2 mole %.

The second gas stream 17 may comprise the light noble gas-depleted stream 23 from the second separation unit 20. The light noble gas-depleted stream 23 may be compressed in compressor 45. The flow rate of light noble gas in the second stream 17 may be increased or decreased by controlling operating conditions of the second separation unit 20 responsive to the measure of the light noble gas content.

The molar flow rate of light noble gas, F_(2, Noble), in the light noble gas-depleted stream 23 may be increased or decreased in order to maintain the mole fraction of light noble gas in the first separation unit feed gas stream 12 relatively constant in order to maintain operation within a desired light noble gas recovery range.

The second gas stream 17 may further comprise a portion 28 of the light noble gas-rich stream 25. The flow rate of the light noble gas in the second gas stream 17 may be increased by increasing the flow rate of the portion 28 of the light noble gas-rich stream 25 and decreased by decreasing the flow rate of the portion 28 of the light noble gas-rich stream 25.

The portion 28 may be a divided portion or a separated portion of the light noble gas-rich stream 25.

In the process, the second separation unit may be a membrane separation unit. The membrane separation unit separates a feed stream into a non-permeate stream and a permeate stream. The non-permeate stream is the light noble gas-depleted stream 23. The permeate stream is the light noble gas-rich stream 25.

Controlling the operating conditions of the membrane separation unit may comprise increasing the flow rate of light noble gas in the light noble gas-depleted stream 23 by decreasing the pressure difference between the membrane separation unit feed gas stream and the light noble gas-rich stream. Controlling the operating conditions of the membrane separation unit may comprise decreasing the flow rate of light noble gas in the light noble gas-depleted stream by increasing the pressure difference between the membrane separation unit feed gas stream and the light noble gas-rich stream.

The membrane separation unit may comprise a plurality of membrane modules. Controlling the operating conditions of the membrane separation unit may comprise increasing the flow rate of light noble gas in the light noble gas-depleted stream 23 by decreasing the number of membrane modules on-stream. Controlling the operating conditions of the membrane separation unit may comprise decreasing the flow rate of light noble gas in the light noble gas-depleted stream 23 by increasing the number of membrane modules on-stream.

As discussed above, the apparatus may comprise a heat exchanger 40. The operating conditions of the membrane separation unit 20 may be controlled by increasing or decreasing the temperature of the membrane separation unit feed gas stream 21 in a heat exchanger.

Controlling the operating conditions of the membrane separation unit may comprise increasing the temperature of the membrane separation unit feed gas stream 21 to decrease the flow rate of light noble gas, F_(2, Noble), in the light noble gas-depleted stream 23. Controlling the operating conditions of the membrane separation unit may comprise decreasing the temperature of the membrane separation unit feed gas stream 21 to increase the flow rate of light noble gas, F_(2, Noble), in the light noble gas-depleted stream 23.

In the process, the second separation unit 20 may be an adsorption-type separation unit. The adsorption-type separation unit separates a feed stream into a tail gas stream and a product stream. The tail gas stream is the light noble gas-depleted stream 23. The product stream is the light noble gas-rich stream 25.

The adsorption-type separation unit may operate with an adsorption cycle having a cycle time. Controlling the operating conditions of the second separation unit 20 may comprise increasing the cycle time of the second separation unit 20 to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or decreasing the cycle time of the second separation unit 20 to increase the flow rate of light noble gas in the light noble gas-depleted stream 23. When the cycle time is increased, the capacity during production step for the more adsorbable species increases, due to the improved efficiency of removing the more adsorbable species over longer tail gas generation step times. By improving the capacity for the more adsorbable species, less of the desirable, less adsorbable species (light noble gas) is captured and lost during the steps which produce tail gas.

The adsorption-type separation unit may have a feed gas header, and controlling the operating conditions of the second separation unit 20 may comprise increasing the pressure of the second separation unit feed gas stream 21 in the feed gas header of the second separation unit 20 to decrease the flow rate of the light noble gas in the light noble gas-depleted stream 23, and/or decreasing the pressure of the second separation unit feed gas stream 21 in the feed gas header of the second separation unit 20 to increase the flow rate of the light noble gas in the light noble gas-depleted stream 23. When the feed pressure is increased, the capacity during the production step for the more adsorbable species increases, due to the improved efficiency of the adsorbent at higher pressures to adsorb more adsorbable species. By improving the capacity for the more adsorbable species, less of the desirable, less adsorbable species (light noble gas) is captured and lost during the steps which produce tail gas.

The adsorption-type separation unit may have a tail gas header, and controlling the operating conditions of the second separation unit 20 may comprise increasing the pressure of the light noble gas-depleted stream 23 in the tail gas header of the second separation unit 20 to increase the flow rate of the light noble gas in the light noble gas-depleted stream 23, and/or decreasing the pressure of the light noble gas-depleted stream 23 in the tail gas header of the second separation unit 20 to decrease the flow rate of the light noble gas in the light noble gas-depleted stream 23. When the pressure of the light noble gas-depleted stream 23 is increased, the capacity during the production step for the ore adsorbable species decreases, due to the lower quantity of the more adsorbable species being removed during the tail gas generating steps. By decreasing the capacity for the more adsorbable species, more of the desirable, less adsorbable species (light noble gas) is captured and lost during the steps which produce tail gas.

The adsorption-type separation unit may operate with an adsorption cycle comprising a blowdown step having a target pressure for the end of the blowdown step, where a blowdown gas stream is formed during the blowdown step. The blowdown gas may be compressed to form a rinse gas stream and/or the blowdown gas may be passed to the tail gas header. Controlling the operating conditions of the second separation unit 20 may comprise increasing the target pressure for the end of the blowdown step to increase the flow rate of the light noble gas in the light noble gas-depleted stream 23, and/or decreasing the target pressure for the end of the blowdown step to decrease the flow rate of the light noble gas in the light noble gas-depleted stream 23. For the case where the blowdown gas is compressed to form a rinse gas stream, increasing the target pressure for the end of the blowdown step results in less of the light noble gas being removed, captured, and returned to the adsorbent bed on the production step via the rinse step. Therefore, more of the light noble gas remains in the bed for the following step(s) that generate tail gas (evacuation and/or purge), so this increases the amount of light noble gas in the noble gas depleted stream.

The adsorption-type separation unit may comprise a plurality of adsorption beds and operate with a plurality of adsorption cycles each comprising a feed step. Controlling the operating conditions of the second separation unit 20 may comprise changing to an adsorption cycle having fewer adsorption beds simultaneously on the feed step to increase the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or changing to an adsorption cycle having a greater number of adsorption beds simultaneously on the feed step to increase the flow rate of light noble gas in the light noble gas-depleted stream 23. When the number of adsorption beds simultaneously on the feed step is decreased, the capacity during the production step for the more adsorbable species decreases, due to the decreased volume of adsorbent available on the feed/production step. By decreasing the capacity for more adsorbable species, more of the desirable, less adsorbable species (light noble gas) is captured and lost during the steps which produce tail gas.

The adsorption-type separation unit may comprise a plurality of adsorption beds and operate with a plurality of adsorption cycles some comprising a pressure equalization step. Controlling the operating conditions of the second separation unit 20 may comprise changing to an adsorption cycle having fewer or no pressure equalization steps to increase the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or changing to an adsorption cycle having a greater number of pressure equalization steps to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23. When the number of pressure equalizations is decreased, the capacity during the production step for the more adsorbable species decreases, due to the decreased efficiency of removing the more adsorbable species during the pressure equalization steps. By decreasing the capacity for the more adsorbable species, more of the desirable, less adsorbable species (light noble gas) is captured and lost during the steps that produce tail gas.

In the process, the second separation unit 20 may be a distillation-type separation unit. The distillation-type separation unit separates a feed stream into a bottoms stream and an overhead or distillate stream. The bottoms stream is the light noble gas-depleted stream 23. The overhead or distillate stream is the light noble gas-rich stream 25.

The distillation-type separation unit may operate at an operating pressure. Controlling the operating conditions of the second separation unit 20 may comprise decreasing the operating pressure of the second separation unit 20 to increase the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or increasing the operating pressure of the second separation unit 20 to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23. When the operating pressure is increased, the solubility of the light noble gas in the bottoms stream is increased, which increases the flow rate of the light noble gas in the light noble gas-depleted stream.

The distillation-type separation unit may operate at an operating temperature. Controlling the operating conditions of the second separation unit 20 may comprise decreasing the operating temperature of the second separation unit 20 to increase the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or increasing the operating temperature of the second separation unit 20 to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23. When the temperature is increased, the solubility of the light noble gas in the bottoms stream is increased, which increases the flow rate of the light noble gas in the light noble gas-depleted stream.

The distillation-type separation unit may operate with a reflux ratio. Controlling the operating conditions of the second separation unit 20 may comprise increasing the reflux ratio of the second separation unit 20 to increase the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or decreasing the reflux ratio of the second separation unit 20 to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23. When the reflux ratio is increased, the amount of reflux flow is increased in relation to the amount of overhead or distillate flow, which ‘washes’ more light noble gas into liquid solution in the distillation-type separation unit and therefore the bottoms stream, thereby increasing light noble gas-depleted stream flow.

The distillation-type separation unit may operate with a distillate to feed ratio. Controlling the operating conditions of the second separation unit 20 may comprise increasing the distillate to feed ratio of the second separation unit 20 to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or decreasing the distillate to feed ratio of the second separation unit 20 to increase the flow rate of light noble gas in the light noble gas-depleted stream 23. When the distillate to feed ratio is increased, the amount of distillate flow is increased in relation to the amount of feed flow, which decreases the amount/quantity of light noble gas in the distillation-type separation unit and therefore the bottoms stream, thereby decreasing light noble gas-depleted stream flow.

The distillation-type separation unit may operate with a boilup ratio. Controlling the operating conditions of the second separation unit 20 may comprise increasing the boilup ratio of the second separation unit 20 to decrease the flow rate of light noble gas in the light noble gas-depleted stream 23, and/or decreasing the boilup ratio of the second separation unit 20 to increase the flow rate of light noble gas in the light noble gas-depleted stream 23. When the boilup ratio is increased, the amount of vapor flow to the bottom stage is increased in relation to the amount of bottoms flow, which evaporates the light noble gas from the bottoms stream, thereby decreasing light noble gas-depleted stream flow.

The term “reflux ratio” is a standard term in the distillation art and is the ratio of reflux flow rate to overhead or distillate flow rate. The term “distillate to feed ratio” is a standard term in the distillation art and is the ratio of distillate flow rate to feed flow rate. The term “boilup ratio” is a standard term in the distillation art and is the ratio of boilup or vapor to the bottom stage flow rate to bottoms flow rate.

Any required pretreatment of gaseous feed mixtures to the various separation units, or post-treatment of any of the product streams can be employed with this process and apparatus, as required or desired. For example, depending upon the choice of the adsorbents used, a pretreatment to remove certain components from the feed gas stream 11 which might have an adverse effect on the adsorbent or process may be required. Similarly, it is possible to have components in the final helium product, i.e. the helium-rich permeate stream 25, which may be undesirable in the subsequent use of this product stream and must be removed in a post-treatment operation prior to its use.

EXAMPLES Example 1

A multiple-bed adsorption pilot unit/experimental apparatus was set up to gather light noble gas recovery data for an adsorption separation unit. The unit consisted of 5 adsorption beds, each 2.21 cm (0.87 in.) inside diameter by 3.05 m (10 ft.) in length. The adsorption cycle utilized is shown in FIG. 2, which is a 5-bed vacuum swing adsorption (VSA) with a rinse step (described above). The beds were filled with activated carbon adsorbent and the cycle time onstream varied between 30 seconds, 60 seconds, and 120 seconds. The feed composition to the unit was varied between 0.35 mole % He to 4 mole % He with nitrogen, methane, and carbon dioxide making up the balance of the feed gas. The feed pressure was varied between 345 kPa (absolute) and 1029 kPa (absolute) and the feed temperature was 21.1° C. (70° F.). The optional buffer tank 30 was included in the experimental set up and product purity was measured at the outlet from this tank, which is equivalent to second separation unit inlet stream 21 in FIG. 1.

In the first experiment, varying amounts/concentrations of helium were fed to the experimental apparatus and the overall helium recovery was measured. The curve titled “AP Experimental System” in FIG. 4 shows the results of varying feed helium mole % to the adsorption unit with 70 mole % helium product purity and a 1:1 Rinse to Feed ratio for all data points on said curve. From FIG. 4, it can be seen that operating on the right side (higher helium feed gas concentrations) of FIG. 4 is more beneficial to overall system helium recovery. In practice, the feed gas helium concentration in stream 11 of FIG. 1 varies and declines with time.

Therefore, maintaining the helium concentration to the adsorption unit brings value and benefit. Higher helium concentration to the adsorption unit could be achieved by recycling helium from a second downstream separation unit. However, recycling helium from a second downstream separation unit is counter-intuitive because the (first) adsorption separation unit is the only source of helium losses, leading to lower helium recovery. But if helium recovery from the (first) adsorption separation unit could be improved to the point where benefits of additional helium feed concentration outweigh the helium losses, this would provide non-obvious benefits.

In another set of experiments, the experimental system was operated with varying secondary volume, V₂. FIG. 5 shows experimental results of the adsorption-type system in the present invention on helium recovery as a function of varying secondary volume. Data in FIG. 5 is with 2 mole % helium in the feed and a 1:1 Rinse to Feed ratio. Rinse to Feed ratio is a measure of the molar flow of gas (stream 18 FIG. 1) taken from the bed during the Rinse step divided by the molar flow of feed gas (stream 12 in FIG. 1) gas sent to the bed in the Feed step. This ratio is monitored and controlled by the pressure in the bed at the end of the Blowdown step. In the experimental system, this was performed by adding isolation valves to the feed and product end of the column/bed, effectively reducing secondary volume. From the FIG. 5, it is clear that decreasing secondary volume will increase helium recovery.

From the experimental results, another unexpected benefit to maintaining adsorption unit feed (stream 12 in FIG. 1) is observed, which is illustrated in FIG. 6. As the adsorption unit feed gas (stream 12 in FIG. 1) declines, the helium product purity from the adsorption unit (stream 21 in FIG. 1) also declines. Since the feed concentration is known to vary and decline with time, this variation with product purity of the second unit inlet stream 21 may lead to difficulty controlling the second separation unit. Additionally, since there is a finite/practice design basis for the second separation unit, these variations could lead to a decline of light noble gas rich stream 25. Decline of the light noble gas rich stream 25 below the required purity for light noble gas might force the unit to be significantly turned down or potentially shut down.

Example 2

The present invention aims to maximize light noble gas recovery while handling varying and low concentrations of light noble gas in the feed by recycling a second stream rich in light noble gas to enrich the light noble gas content in the feed to the adsorption separation unit. From the findings in the experimental system, there has been an intentional effort to maximize helium recovery over the prior art by decreasing the secondary volumes of the adsorption unit. The curve titled “Header Changes” in FIG. 4 shows the impact from simulation modeling of reducing the secondary volumes by 50% over a typical commercial system by re-arranging and/or minimizing piping volumes.

The curve titled “Isolation Valve” in FIG. 4 employs an isolation switch valve in fluid communication with the bed at feed and product end of the adsorbent bed. This significantly reduces the secondary volume over the “Header Change” and “Commercial System”, which in turn improves the adsorption and overall system helium recovery. The isolation valve on the product header opens during Production (P), Rinse (R), and Product Pressurization (PP) but closes during Blowdown (BD) and Evac (E). The isolation on the feed header closes during Product Pressurization (PP) and is open during all other adsorption steps to prevent gas having high helium concentrations from entering the secondary volumes on the feed end of the bed.

By reducing the secondary volume by header changes or isolation valves, the helium recovery at all combined gas stream 12 concentrations is significantly improved over the prior art and enables the present invention to achieve higher recovery across the whole range of helium concentration of interest (0.1% to 4%), as shown in FIG. 4.

Example 3

Greater benefits are seen in the case when the helium content of the incoming feed gas stream 11 drops from 4% to 0.5% over time. The prior art in this example is U.S. Pat. No. 8,268,047, a double VPSA for helium recovery. This change in the helium content of the feed gas stream 11 will cause a decrease in the helium purity of the adsorption unit enriched gas stream 13 as shown in FIG. 6.

Due to the lower incoming purity to the second stage inlet, the prior art, given a fixed system already in operation, would have to ‘short cycle’ (well known to someone skilled in the art of adsorption) the final purification stage to maintain final helium purity. This inherently increases the second stream helium flow (F_(2, Noble)) which leads to an increased helium loss as evidenced on the curve titled “Prior Art” in the FIG. 7.

In the current invention, due to the minimization of secondary volume in the adsorption separation unit, the adsorption separation unit recovery is implicitly higher, which enables the ability to actively increase the

$\frac{F_{2,{Noble}}}{F_{1,{Noble}}} \geq 1$

as the feed content drops. This yields a significant improvement in helium recovery compared to the Prior Art as the feed content drops, as shown in FIG. 7. 

We claim:
 1. An apparatus for producing a light noble gas product from a feed gas comprising a light noble gas and at least one other gaseous component, the light noble gas selected from the group consisting of helium, and neon, the apparatus comprising: an adsorption separation unit, wherein the adsorption separation unit comprises a plurality of vessels each containing a bed of adsorbent; a feed gas header in selective fluid communication with each of the plurality of vessels; a product gas header in selective fluid communication with each of the plurality of vessels; a tail gas header in selective fluid communication with each of the plurality of vessels; process gas transfer lines operatively connecting the plurality of vessels to the feed gas header, the product gas header, and the tail gas header; each vessel of the plurality of vessels having process gas transfer lines associated therewith; a plurality of valves in the process gas transfer lines including a plurality of valves adjacent and associated with each respective vessel; wherein the adsorption separation unit has a central volume of process gas transfer lines associated with each of the respective vessels, V_(c); wherein the central volume for each respective vessel is the sum of (i) the volume contained in the process gas transfer lines associated with the respective vessel connecting the respective vessel to each valve adjacent the respective vessel, (ii) all dead-end volumes, if any, connected at a junction to the respective vessel, and (iii) all dead-end volumes, if any, connected at a junction to any of the process gas transfer lines associated with the respective vessel that connect the respective vessel to any valve adjacent the respective vessel; wherein the central volume for each respective vessel includes a secondary volume, V₂, where the secondary volume is the sum of (i) the volume of all dead-end volumes, if any, connected to the respective vessel; (ii) the volume of all dead-end volumes, if any, connected at a junction to any of the process gas transfer lines associated with the respective vessel that connect the respective vessel to any valve adjacent the respective vessel, and (iii) the volume of any process gas transfer lines, if any, having a first end terminating in a valve adjacent the respective vessel that is configured to permit transfer of process gas to the tail gas header when open and having a second end terminating at a junction to any other of the associated process gas transfer lines that connect the respective vessel to any other valve adjacent the respective vessel; and wherein the secondary volume V₂ is less than 5% of the central volume V_(c) for each vessel.
 2. The apparatus according to claim 1 further comprising: a second separation unit, the second separation unit having an inlet, a first outlet, and a second outlet, the inlet in fluid communication with the product gas header of the adsorption separation unit; a gas mixer having a first inlet for receiving a stream of the feed gas, a second inlet in fluid communication with a source of a second gas having a higher light noble gas concentration than the feed gas, wherein the feed gas header of the adsorption separation unit is in downstream fluid communication with the outlet of the gas mixer; a sensor in at least one of (i) a process gas transfer line supplying the first inlet of the gas mixer, (ii) a process gas transfer line connecting the outlet of the gas mixer to the feed gas header of the adsorption separation unit, and (iii) the feed gas header; and a controller in signal communication with the sensor, the controller operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer responsive to signals from the sensor.
 3. The apparatus according to claim 2 wherein the source of the second gas comprises the first outlet of the second separation unit.
 4. The apparatus according to claim 2 wherein the source of the second gas comprises the second outlet of the second separation unit.
 5. The apparatus according to claim 2 wherein the source of the second gas comprises a process gas transfer line which operatively connects the product gas header to the inlet to the second separation unit.
 6. The apparatus according to claim 2 wherein the gas mixer has a third inlet in fluid communication with the second outlet of the second separation unit.
 7. The apparatus according to claim 2 wherein the gas mixer has a third inlet in fluid communication with a process gas transfer line which operatively connects the product gas header of the adsorption separation unit to the inlet to the second separation unit.
 8. The apparatus according to claim 2 wherein the second separation unit is a membrane-type separation unit, wherein the source of the second gas comprises the first outlet of the second separation unit; and wherein at least one of (a) the second separation unit comprises one or more adjustable orifices in signal communication with the controller, the one or more adjustable orifices operative to control a pressure in the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the one or more adjustable orifices; (b) the membrane-type separation unit comprises a plurality of membrane modules and one or more control valves that control the fraction of membrane modules on-stream, the one or more control valves in signal communication with the controller; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the fraction of membrane modules on-stream; or (c) the apparatus comprises a heat exchanger operative to control a temperature in the second separation unit, the heat exchanger in signal communication with the controller; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the heat duty of the heat exchanger.
 9. The apparatus according to claim 2 wherein the second separation unit is an adsorption-type separation unit, wherein at least one of (a) the source of the second gas comprises the first outlet of the second separation unit; the adsorption-type separation unit comprises a plurality of vessels each containing a bed of adsorbent, and one or more control valves that control the fraction of the plurality of vessels on-stream, the one or more control valves in signal communication with the controller; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the fraction of the plurality of vessels on-stream; (b) the source of the second gas comprises the first outlet of the second separation unit; the second separation unit comprises a feed gas header, the second separation unit comprises one or more adjustable orifices operative to control a pressure in the feed gas header of the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the one or more adjustable orifices operative to control the pressure in the feed gas header of the second separation unit; (c) the source of the second gas comprises the first outlet of the second separation unit; the second separation unit comprises a tail gas header, the second separation unit comprises one or more adjustable orifices operative to control a pressure in the tail gas header of the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the one or more adjustable orifices operative to control the pressure in the tail gas header of the second separation unit; or (d) the source of the second gas comprises the second outlet of the second separation unit; the second separation unit comprises a product gas header, the second separation unit comprises one or more adjustable orifices operative to control a pressure in the product gas header of the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the one or more adjustable orifices operative to control the pressure in the product gas header of the second separation unit.
 10. The apparatus according to claim 2 wherein the second separation unit is a distillation-type separation unit, wherein the source of the second gas comprises the first outlet of the second separation unit; and wherein at least one of (a) the second separation unit comprises one or more adjustable orifices in signal communication with the controller, the one or more adjustable orifices operative to control a pressure in the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the one or more adjustable orifices operative to control the pressure in the second separation unit; (b) the apparatus comprises a heat exchanger operative to control a temperature in the second separation unit, the heat exchanger in signal communication with the controller; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the heat duty of the heat exchanger; (c) the second separation unit comprises one or more orifices operative to control a reflux ratio in the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the reflux ratio in the second separation unit; (d) the second separation unit comprises one or more orifices operative to control a distillate to feed ratio in the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the distillate to feed ratio in the second separation unit; or (e) the second separation unit comprises one or more orifices operative to control a product to feed ratio in the second separation unit; and the controller is operable to control the flow rate of light noble gas from the source of the second gas to the second inlet of the gas mixer by adjusting the distillate to feed ratio in the second separation unit.
 11. A process for separating a feed gas stream comprising a light noble gas and at least one other gaseous component into a light noble gas-rich stream and a light noble gas-lean stream, the light noble gas selected from the group consisting of helium, and neon, the process comprising: combining the feed gas stream with a second gas stream to form a combined gas stream, the second gas stream having higher light noble gas content than the feed gas stream, the second gas stream having a flow rate that is regulated; separating a first separation unit feed gas stream in an adsorption separation unit to produce a light noble gas-enriched stream and the light noble gas-lean stream, wherein the first separation unit feed gas stream comprises at least a portion of the combined gas stream; and separating a second separation unit feed gas stream in a second separation unit to produce the light noble gas-rich stream and a light noble gas-depleted stream, wherein said second separation unit feed gas stream comprises at least a portion of the light noble gas-enriched stream from the adsorption separation unit; wherein the flow rate of the light noble gas in the second gas stream is controlled responsive to a measure of the light noble gas content in at least one of the feed gas stream, the combined gas stream, or the first separation unit feed gas stream.
 12. The process according to claim 11 wherein the adsorption separation unit comprises: a plurality of vessels each containing a bed of adsorbent; a feed gas header in selective fluid communication with each of the plurality of vessels; a product gas header in selective fluid communication with each of the plurality of vessels; a tail gas header in selective fluid communication with each of the plurality of vessels; process gas transfer lines operatively connecting the plurality of vessels to the feed gas header, the product gas header, and the tail gas header; each vessel of the plurality of vessels having process gas transfer lines associated therewith; a plurality of valves in the process gas transfer lines including a plurality of valves adjacent and associated with each respective vessel; wherein the adsorption separation unit has a central volume of process gas transfer lines associated with each of the respective vessels, V_(c); wherein the central volume for each respective vessel is the sum of (i) the volume contained in the process gas transfer lines associated with the respective vessel connecting the respective vessel to each valve adjacent the respective vessel, (ii) all dead-end volumes, if any, connected at a junction to the respective vessel, and (iii) all dead-end volumes, if any, connected at a junction to any of the process gas transfer lines associated with the respective vessel that connect the respective vessel to any valve adjacent the respective vessel; wherein the central volume for each respective vessel includes a secondary volume, V₂, where the secondary volume is the sum of (i) the volume of all dead-end volumes, if any, connected to the respective vessel; (ii) the volume of all dead-end volumes, if any, connected at a junction to any of the process gas transfer lines associated with the respective vessel that connect the respective vessel to any valve adjacent the respective vessel, and (iii) the volume of any process gas transfer lines, if any, having a first end terminating in a valve adjacent the respective vessel that is configured to permit transfer of process gas to the tail gas header when open and having a second end terminating at a junction to any other of the associated process gas transfer lines (102) that connect the respective vessel to any other valve adjacent the respective vessel; and wherein the secondary volume V₂ is less than 5% of the central volume V_(c) for each vessel.
 13. The process according to claim 11 where the feed gas stream has a total gas molar flow rate, F₁, with a molar flow rate of light noble gas, F_(1, Noble), and the second gas stream has a total gas molar flow rate, F₂, with a molar flow rate of light noble gas, F_(2, Noble), and wherein $\frac{F_{2,{Noble}}}{F_{1,{Noble}}} \geq 1.$
 14. The process according to claim 11 wherein the flow rate of light noble gas in the second gas stream is increased if the light noble gas content is less than a desired lower limit; and/or wherein the flow rate of light noble gas in the second gas stream is decreased if the light noble gas content is greater than a desired upper limit.
 15. The process according to claim 11 wherein the second gas stream comprises the light noble gas-depleted stream, and wherein the flow rate of light noble gas in the second stream is increased or decreased by controlling operating conditions of the second separation unit in response to the light noble gas content.
 16. The process according to claim 15 wherein the second separation unit is a membrane-type separation unit comprising a plurality of membrane modules and wherein controlling operating conditions of the second separation unit comprises at least one of (a) decreasing the pressure difference between the second separation unit feed gas stream and the light noble gas-rich stream to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or increasing the pressure difference between the second separation unit feed gas stream and the light noble gas-rich stream to decrease the flow rate of light noble gas in the light noble gas-depleted stream; (b) decreasing the number of membrane modules on-stream to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or increasing the number of membrane modules on-stream to decrease the flow rate of light noble gas in the light noble gas-depleted stream; or (c) increasing the temperature of the second separation unit feed gas stream to decrease the flow rate of light noble gas in the light noble gas-depleted stream; and/or decreasing the temperature of the second separation unit feed gas stream to increase the flow rate of light noble gas in the light noble gas-depleted stream.
 17. The process according to claim 15 wherein the second separation unit is an adsorption-type separation unit wherein at least one of (a) the adsorption-type separation unit operates with an adsorption cycle having a cycle time and controlling the operating conditions of the second separation unit comprises increasing the cycle time of the second separation unit to decrease the flow rate of light noble gas in the light noble gas-depleted stream; and/or decreasing the cycle time of the second separation unit to increase the flow rate of light noble gas in the light noble gas-depleted stream; (b) the adsorption-type separation unit has a feed gas header and controlling the operating conditions of the second separation unit comprises increasing the pressure of the second separation unit feed gas stream in the feed gas header of the second separation unit to decrease the flow rate of the light noble gas in the light noble gas-depleted stream; and/or decreasing the pressure of the second separation unit feed gas stream in the feed gas header of the second separation unit to increase the flow rate of the light noble gas in the light noble gas-depleted stream; (c) the adsorption-type separation unit has a tail gas header and controlling the operating conditions of the second separation unit comprises increasing the pressure of the light noble gas-depleted stream in the tail gas header of the second separation unit to increase the flow rate of the light noble gas in the light noble gas-depleted stream; and/or decreasing the pressure of the light noble gas-depleted stream in the tail gas header of the second separation unit to decrease the flow rate of the light noble gas in the light noble gas-depleted stream; (d) the adsorption-type separation unit operates with an adsorption cycle comprising a blowdown step having a target pressure for the end of the blowdown step and controlling the operating conditions of the second separation unit comprises increasing the target pressure for the end of the blowdown step to increase the flow rate of the light noble gas in the light noble gas-depleted stream; and/or decreasing the target pressure for the end of the blowdown step to decrease the flow rate of the light noble gas in the light noble gas-depleted stream; (e) the adsorption-type separation unit comprises a plurality of adsorption beds and operates with a plurality of adsorption cycles each comprising a feed step and controlling the operating conditions of the second separation unit comprises changing to an adsorption cycle having a lesser number of adsorption beds simultaneously on the feed step to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or changing to an adsorption cycle having a greater number of adsorption beds simultaneously on the feed step to increase the flow rate of light noble gas in the light noble gas-depleted stream; or (f) the adsorption-type separation unit comprises a plurality of adsorption bed and operates with a plurality of adsorption cycles some comprising a pressure equalization step and controlling the operating conditions of the second separation unit comprises: changing to an adsorption cycle having a lesser number of or no pressure equalization steps to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or changing to an adsorption cycle having a greater number of pressure equalization steps to decrease the flow rate of light noble gas in the light noble gas-depleted stream.
 18. The process according to claim 15 wherein the second separation unit is a distillation-type separation unit operating with a reflux ratio and at an operating pressure and an operating temperature, wherein controlling the operating conditions of the second separation unit comprises at least one of (a) decreasing the operating pressure of the second separation unit to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or increasing the operating pressure of the second separation unit to decrease the flow rate of light noble gas in the light noble gas-depleted stream; (b) increasing the reflux ratio of the second separation unit to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or decreasing the reflux ratio of the second separation unit to decrease the flow rate of light noble gas in the light noble gas-depleted stream; or (c) decreasing the operating temperature of the second separation unit to increase the flow rate of light noble gas in the light noble gas-depleted stream; and/or increasing the operating temperature of the second separation unit to decrease the flow rate of light noble gas in the light noble gas-depleted stream.
 19. The process according to claim 11 wherein the second gas stream comprises a portion of the light noble gas-rich stream having a flow rate, and the flow rate of the light noble gas in the second gas steam is increased by increasing the flow rate of the portion of the light noble gas-rich stream and decreased by decreasing the flow rate of the portion of the light noble gas-rich stream.
 20. The process according to claim 11 wherein the feed gas stream has a molar concentration of light noble gas ranging from 0.1 mole % light noble gas to 2.0 mole % light noble gas. 